Chapter 1 Boiler

Indonesia 1660MW Paiton
Coal Fired Thermal Power Plant
Operating and Maintenance Manual
Volume III: Maintenance Manual

Chapter 1: Maintenance Manual of Boiler
Harbin Power Engineering Company Limited
June, 5th, 2009

Content
Part One Maintenance Code for Boiler Proper.......................................................................... 1
Chapter Boiler Proper Heating Surface Maintenance......................................................... 1
Chapter Maintenance Regulation for Pipes and Valves of the Boiler.............................. 24
Chapter Maintenance of Burner and Oil Gun.................................................................. 57
Chapter Soot Blower Maintenance ................................................................................. 64
Part Two Boiler Auxiliary Equipment Maintenance.................................................................... 74
Chapter Coal Mill Maintenance ......................................................................................... 74
Chapter Boiler Coal Feeder Overhaul.............................................................................. 98
Chapter Boiler Raw Coal Hopper Maintenance Regulation.......................................... 112
Chapter Air Compressor Overhaul................................................................................ 113
Chapter Coal Powder Pipe and Its Accessories Maintenance Regulation ................... 124
Chapter Boiler Mill Sealing Air Fan Maintenance Regulation....................................... 127
Chapter Primary Air Fan, Forced Draft Fan and Introduced Draft Fan Maintenance
Regulation ............................................................................................................................. 130
Chapter Air Preheater Maintenance Regulation.......................................................... 162
Part Three Ash Handling System Equipment Maintenance Regulation.................................. 203
Chapter Slag Removing Equipments Maintenance Regulation........................................ 203
Chapter Dry Ash Transportation Equipments Overhaul ................................................ 239
I
Chapter ESP Machinery Equipment Maintenance........................................................ 253
Chapter Pipeline System and Valve Maintenance ....................................................... 272
II
Part One Maintenance Code for Boiler Proper
Chapter Boiler Proper Heating Surface Maintenance
. General
1.1 Applicable scope: This chapter of maintenance regulation is applicable to boiler proper
heating surface of Indonesia Paiton 1660MW coal fired power plant.
1.2 Quoted materials:
Twenty five Key Requirements on Prevention of Major Accidents Requirements in Electric Power
Generation
Guide of Maintenance of Boiler Unit for Thermal Power Plant Part Two Boiler Proper
Maintenance DL/T 748.2
The Code of Erection and Acceptance of Electric Power Construction Section of Welding of
Thermal Power Plant DL50071992
Technical Supervision Codes for Metal in Thermal Power Plants DL 4382000

Daishan Power Plant Boiler Maintenance Regulations
. B&WB-2028/17.5-M Boiler Brief Introduction

2.1 Boiler proper system equipments
2.1.1 Boiler brief introduction
Indonesia Paiton 1660MW coal fired power plant adopts the sub-critical parameter RBC
boiler to be executed with performance structure optimizing design by Harbin Boiler Company
Limited combined with characteristics of designed coal and checked coal and natural conditions.
(1) Boiler has a single furnace with swing type DC burners arranged in the four corners,
tangential burning, equipped with six (6) middle-speed miller and positive pressure direct blowing
system. For the burners in every corner, there are six (6) layers of primary air nozzles and the
burners can swing up and down with maximum primary air swing angle of 27 and secondary air
of 30. In BMCR working condition, five (5) mills are in operation and the rest one (1) is in
standby.
(2) Wall type radiant reheaters and long distance superheater isolation plates are installed for
up section of the furnace to enhance the radiation of the reheaters and superheaters. Wall type
radiant reheaters lie at up furnace rear wall and two side walls. Six (6) isolation plates are installed
in the direction of boiler width and functions as cutting the revolving gas flow to reduce the
temperature difference of gas that entering into horizontal gas duct in direction of boiler width.
(3) Forcing recycle system of rifled tube membrane cooling water wall is adopted to decrease
boiler recycle rate to about 2 for using circulating pump with low head pump to reduce power
consumption and improve its running reliability. Water circulation of every kind of working condition
of cooling water wall loop is accurately calculated by computer to ensure its reliability. Membrane
cooling water wall is welding type of plain tube adding with flat steel.
(4) Steam cooling fixing pipes and hanging pipes are furthest adopted for all stages
superheaters and reheaters to ensure reliable operation. At splitter plate and rear plate along
furnace width, there are six (6) groups of steam cooling fixing clamping pipes, between which and
wall type reheaters guide device is installed to fix and clamp the tube plates to avoid shaking
during operation. Steam cooling fixing pipe crossing through furnace are installed for fixing
superheater rear plate and reheater front plate to keep transverse space between plates and avoid
shaking during operation. Water cooling type hanging pipes introduced from outlet header of
economizer are adopted for suspending and fixing horizontal low temperature superheater
arranged in rear gas duct. Economizer adopts metal supporters for fixing. For the pipe plates
1
(superheater splitter plate, superheater rear plate, reheater front plate) in high temperature section,
the most inside pipe rings are prolonged for clamping bottom pipes of pipe plates.
(5) According to home operation experience and characteristics of designed coal, reasonable
gas speed is adopted in design of convection heating surface.
(6) Biggish transverse pitch is adopted for all stages superheaters and reheaters to avoid slag
and ash on heating surface and, to be convenient for installing sealing devices at place where
coiled pipes crossing roof to improve the seal of boiler roof.
(7) Pipes with biggish diameters, such as57, 60 and 63 are adopted for all stages
superheaters and reheaters. To enhance pipe rigidity during manufacturing and installation, which
would benefit reduce resistance of superheater and reheater. For such biggish diameter pipes,
aligned arrangement benefits for both reducing abrasion at air side of the pipe and improving its
abrasion resistant ability.
(8) Single or several big diameter connection pipes are adopted for connection between
stages of superheaters and reheaters to mix steam effectively and avoid error. Big diameter tee
pipes are adopted for connecting headers and big diameter connection pipes.
(9) Materials of coiled pipes of superheaters and reheaters are selected on the basis of
accurate calculation by computer of wall temperature, resistance and flow distribution, and ASME
normative seamless pipes are adopted for all big diameter headers and connection pipes on the
base of ensuring their performance and intensity.
(10) Boiler is arranged in the open air and its frame adopts steel structure entirely.
(11) Two double seal air preheaters are installed for each boiler and the air preheater is
backspin type.
(12) Direct effect spring type safety valves are installed for boiler barrel, superheater outlet
and reheater outlet. Four (4) dynamical control valves (ERV) are installed at outlet of superheater
to reduce actuation times of the safety valve.
(13) Steam temperature regulation methods: Two (2) stages spray water are adopted for
superheater to eliminate steam temperature difference at left and right of superheater outlet. The
first stage spray water attemperator, having one point respectively on left and right, is installed on
big diameter connection pipe between low temperature superheater and splitter plate. The second
stage spray water attemperator, having one point respectively on left and right, is installed on big
diameter connection pipe between superheater rear plate and final stage superheater.
Attemperator adopts flute pipe type. Temperature regulation is mainly realized by burner swing
and two (2) atomizing nozzle type water spraying attemperators are installed on inlet guide pipe of
superheater for emergency water spraying. Excessive air coefficient changing also has a certain
effect on temperature regulation of superheater and reheater.
(14) Different types of soot blower are installed at furnace, all stages convection heating
surfaces and rotary air preheater, soot blowers operation adopts program control. All the wall soot
blowers and retractable soot blowers can work for once within 24 hours according to fired coal
and ash agglomeration on heating surface. All the soot blowing system and its program control is
supplied by Shanghai Clyde Machinery Co., Ltd.
(15) Besides calculating elements intension of pressurized parts according to ASME code,
secondary stress influencing intension has also been sufficiently considered; stress in main pipe
system and many special area has been widely analyzed to ensure its reliability.
(16) An expansion center has set for boiler and precise thermal displacement calculation can
be done for analysis basis of expansion compensation, clearance reservation and pipe system
stress and for convenience of matching pressure condition of pipelines designed by design
institute. Same calculation also has been considered in design of rigid beam, sealing structure and
boom. Set of expansion center has a significant function for boiler reliable operation and seal
improvement.
(17) Boiler rigid beam should be designed according to maximum instant pressure in furnace
of 8.7kPa. This designed pressure is considering of instant maximum negative pressure in
2
furnace caused by main fuel trip and FDF stop in emergency accident. This data complies with
regulations of national fire proof association (NFPA). During boiler horizontal rigid beam
arrangement, maximum permit spaces should be confirmed according to conditions of designed
pressure at gas side, span and pipe stress of all parts through stress analysis, rigid beams actual
span confirmed according to specific conditions such as gate opening arrangement should be
lower than maximum permit span at the premise. Due to the span of two sides at boiler horizontal
gas duct part is the biggest, two vertical rigid beams are set at each side to connect horizontal rigid
beam to reduce deflection.
(18) Start drainage water bypass with capacity of 5% is installed at header under shaft of
boiler tail. When starting the boiler, this bypass is used for draining water to accelerate
temperature rise of superheater. This 5% capacity bypass can meet the requirements of unit cold
and hot state start.
(19) Furnace Safeguard Supervisory System (FSSS) is installed in boiler for stopping unit in
accident and stopping or starting auxiliary equipments.
(20) Coordination control system is installed for the unit for coordination control between
turbine and boiler. It takes boiler and turbine as a whole system for boiler self-regulation.
(21) The unit can run with fixed pressure and also sliding pressure. During boiler start or boiler
runs with low load, sliding pressure operation is adopted to obtain high economic efficiency.
Mechanical slag removing is adopted for ash removing in ash bunker bottom of boiler, slag
removing equipment such as slag hopper and submerged scraper are used.
64 wall type soot blowers are arranged at furnace section, 48 long journey retractable soot
blowers are arranged in furnace up section and convection gas duct area, 1 retractable soot
blower is arranged at every gas inlet and outlet of each air preheater; all the soot blowers are
controlled through program.
Seventeen (17) spring safety valves are set for boiler proper part with arrangement at drum,
superheater outlet pipe, reheater inlet & outlet pipe, among which three (3) are respectively at left
and right side of drum head, two (2) at superheater outlet pipe, seven (7) at reheater inlet pipe and
two (2) at reheater outlet pipe. Two (2) motor-driven release valves are respectively set at
superheater outlet pipe A, B.
In addition, furnace flame video camera device, drum water level indicator and water level
video camera device and safety protection devices such as furnace outlet gas temperature
detector, boiler pipe leakage automatic alarm device etc.
2.1.2 Main performance parameters of the boiler
Name Unit BMCR (693MW)
Boiler maximum continuous rating (B-MCR) t/h 2187.13
Superheater outlet steam pressure MPa(g) 17.5
Superheater outlet steam temperature 541
Reheater steam flow t/h 1839.8

Reheater inlet steam pressure MPa(g) 4.025
Reheater outlet steam pressure MPa(g) 3.835
Reheater inlet steam temperature 338.1
Reheater outlet steam temperature 541
Economizer inlet feedwater temperature 281.4
Boiler barrel design pressure MPa(g) 19.9
3
Reheater design pressure MPa(g) 4.6
Boiler ensured heat efficiency (as per low heating value ) 85.45
Name Unit TMCR (660MW)

Boiler maximum continuous rating (B-MCR) t/h 2064.1
Superheater outlet steam pressure MPa(g) 17.40
Superheater outlet steam temperature 541
Reheater steam flow t/h 1742.4

Reheater inlet steam pressure MPa(g) 3.81
Reheater outlet steam pressure MPa(g) 3.63
Reheater inlet steam temperature 332.3
Reheater outlet steam temperature 541
Economizer inlet feedwater temperature 282.7
Attemperator water temperature (HP heater inlet) 281.4
Boiler barrel design pressure MPa(g) 19.9

Reheater design pressure MPa(g) 4.6
Boiler ensured heat efficiency (as per low heating value ) 85.46
. Boiler Proper Maintenance

3.1 Equipment brief introduction and parameters
3.1.1 Drum
3.1.1.1 Brief introduction
Boiler barrel is made from SA-299 carbon steel material with inner diameter of 1778mm(70)
and straight section of 28450mm, and spherical sealing heads are adopted for the two ends. The
thickness of up and down section of boiler barrel are different with up section of 182mm and down
section of 153mm. Ring sandwich structure is adopted inside boiler barrel for channels of
steam-water mixture to make temperatures of up and down wall of boiler barrel even that would
quicken boiler start and stop. 124 cyclone separators with diameter of 254mm are arranged in
boiler barrel with maximum steam flow of 17.64t/h of each separator.
Saturation steam eduction socket, steam water mixture introducing socket, discharge valve
socket and auxiliary steam socket are installed on top of boiler barrel; big diameter downcomer
socket and feedwater socket are installed at bottom of boiler barrel; manhole, safety valve socket,
continuous blowdown socket and high & low water level indicator sockets are installed on head.
Welding should not be done on boiler barrel at site.
The devices inside boiler barrel are to separate water from the steam produced in cooling
water wall and to reduce dissolving salt content in steam to be lower than regulated standard.
Generally, steam water separation includes three phases, former two of which are completed in
cyclone separator and the third operation is at top section of boiler barrel, and is completed before
steam entering into saturation steam eduction pipe.
Steam-water mixture produced in cooling water wall enters into top section of boiler barrel
(W-9) through steam-water eduction pipe (W-31), and then flows from two sides through narrow
channel formed by dampers along whole boiler barrel length; due to damper and boiler barrel shell
4
are concentric, steam-water mixture has a constant speed and heat transfer rate, which makes
boiler barrel be under a same temperature constantly. Steam-water mixture turns to upward at
down edge of damper and enters into two cyclone separators.
The secondary separation is realized in cyclone separator.
The first separation is produced between the two concentric cylinders. When moving upward
and entering into inner cylinder of cyclone separator, steam-water mixture produces acentric
rotating movement under force of rotating blade, which makes the heavier water flow upwards
along inner cylinder wall and turn downwards when meeting with turning plate bending at top of
inner cylinder, and flow back to boiler barrel through channel between two cylinders. The
separated steam flows upwards continuously for the second separation.
The second separation is completed in two groups of wave type thin plates arranged tightly at
top of cyclone separator. When goes through zigzag channel between thin plates and due to
inertia, water contained in steam hits onto wave type thin plates; and due to the steam speed is not
very high, this water wont be brought up again. Thus, the separated water flows down along ripple
plates and drops along the wave plates edge at steam outlet.
After the second separation, steam flows upwards for the third (the last) separation. Several
rows of shutter separators are arranged along boiler barrel length at top of boiler barrel and
drainage water pipelines are installed among rows; when steam goes through zigzag channel
between shutter bending plates in quite a low speed, residual water in steam will accumulate on
wave type plate and the water wont be brought up again but flows along wave plates to drainage
pipes, from which these water flows back to boiler barrel.
3.1.1.2 Boiler barrel water level control value:
Normal water level: Under boiler barrel center line 229mm
Permit water fluctuation value: Normal water level 50mm
Alarm water level: Normal water level +127mm
-178mm
Boiler shutdown water level: Normal water level +254mm
-381mm
Sockets and corresponding valves for I&C measuring, dosing, continuous blowdown, boiler
water and steam sampling are installed on boiler barrel, and sockets, corresponding valves, local
water indicators and balancing vessels are installed for boiler barrel water level alarm and
protection.
3.1.1.3 Technical specification
Specification
Name Name Specification and model
and model
Saturation steam
Straight section length 15925mm(eduction
28450mm eduction socket
of boiler barrel pipe: 15918mm)
specification
Drum total length Saturation steam
30504mm 29 pieces
(including head) eduction socket quantity
Assembly parts
Inner diameter 1778mm(70)
Saturation steam eduction pipe is
eduction socket material
SA-106B
15925mm
Steam-water introducing
Outer diameter 2113mm (introducing pipe:
socket specification
15918mm)
5
Drum center nominal Steam-water introducing
78442mm 87 pieces
height socket quantity
Assembly parts
Barrel body and head
SA299
Steam-water introducing eduction pipe is
material socket material
SA-106B
Downcomer pipe tie-in

Total weight of drum 265.423T SA106C
material
Downcomer pipe tie-in
Designed pressure 19.9MPa 6 pieces
material
Maximum working Feedwater pipe bushing
18.83MPa 3 pieces
pressure connection
Safety valve socket
Designed temperature 366 6 pieces
quantity
Hydraulic test pressure 29.85MPa Wave panel separator 164 pieces
Drum water capacity 66m3 Cyclone separator 254mm, 124 pieces
Water supplying pipe
16810mm
specification
Water supplying pipe
1 piece
quantity
3.1.2 Cooling water wall
3.1.2.1.1 Cooling water wall consists of pipes with outer diameter of 515.6MWT/516.5 and
pitch of 63.5mm; clearance in-between pipes are welded with flat steel to completely seal the gas.
Furnace flame fold angle section consists of pipes with outer diameter of 63.5mm and pitch
of 76.2mm; clearance in-between pipes are welded with flat steel.
Furnace extending side wall is made by welding pipes with outer diameter of 63mm and
pitch of 127mm with continuous fin.
Roof pipes on top of furnace are pipes with outer diameter of 63/57mm which are welded
with subsection fin with pitch of 127mm.
After installation of subsection fin pipes, unexposed surface should be poured with fire
resistant concrete and then covered with seal plate. Sealing welding should be done at links to
prevent gas from leaking.
For superheater subassembly perforation, suspending pipe perforation, watching holes and
soot blowing holes formed by pipes bending towards forth, the clearance between pipes and
openings should be sealed by fin to form complete metal surface exposures to gas.
Heat insulation material should be poured to horizontal rigid beam at every layer to from
continuous heat insulation belt around furnace to prevent gas from leaking from clearances
between shielding plates and cooling water wall. Heat insulation material should be filled at vertical
rigid beam and shear angle.
Furnace cooling water wall, horizontal gas duct and tail gas wall are made up of heat
insulation material, which is fixed by pins welded on unexposed surface of cooling water wall and
by wire netting at shear angles. The outer layer of furnace wall is covered with trapezium wave
galvanized shielding plates.
Burner hole, watching hole, manhole and soot blowing hole are opened on cooling water wall.
Rope holes are arranged on the roof of furnace for maintenance. Big air box are welded on cooling
water wall through combined joist frame. Cooling water wall, its up section furnace wall and rigid
6
beam are hanged on top plate through cooling water wall hanging device and expands in designed
expansion direction.
3.1.2.1.2 Technical specification
No. Specification Material Explanation Remark
1 Rifled tube 515.6MWT SA-210A1 Rear cooling water wall up
section
2 516.5 SA-210A1
Rifled tube 63.57.112MWT SA-210A1 Rear cooling water wall
down section
Rifled tube 515.6MWT SA-210A1
Rifled tube 515.6MWT SA-210A1 Front cooling water wall
516.5 SA-210A1
Rifled tube 515.6MWT SA-210A1 Side cooling water wall
516.5 SA-210A1
Rifled tube 63.57.112MWT SA-210A1 Cooling water wall corner
separate tube
Rifled tube 515.6MWT SA-210A1
638 SA-210A1
63.514 SA-210C
Cooling water wall hanging
tube
3.1.3 Superheater
Superheater mainly consists of five (5) parts: a) final stage superheater; b) superheater rear
plate; c) superheater splitter plate; d) vertical low temperature superheater and horizontal low
temperature superheater; e) roof superheater and rear gas duct enclosure wall system.
3.1.3.1.1
Final stage of superheater lies in horizontal gas duct behind rear cooling water wall rack pipe,
which are 104 pieces totally with diameter of 57 and arranged along whole boiler length with
pitch of 190.5mm.
Superheater rear plates lie before flame fold angle above furnace and have 34 pieces with
diameter of 57, 51 and, arranged along whole boiler length with pitch of 571.5mm.
Superheater splitter plates lie above furnace and between front wall cooling water wall and
superheater rear plate; six (6) big pieces are arranged along boiler width and each big piece is
divided into eight (8) small pieces in boiler length direction. Pipes with diameter of 51 are
arranged along whole boiler width with transverse pitch of 2857.5mm and 4064mm respectively
from the center of the furnace.
Vertical low temperature superheater lies in turning room of tail gas duct and above horizontal
low temperature superheater, and is 132 pieces with pipe diameter of 63 and arranged along
whole boiler width with transverse pitch of 152mm.
Horizontal low temperature superheater lies above economizer of tail shaft gas duct, and is
132 pieces with pipe diameter of 57 and arranged along whole boiler width with transverse pitch
of 152mm.
Roof superheater and rear gas duct enclosure wall system consists of roof pipe, side wall,
front wall, rear wall and rear gas duct extending enclosure wall. It is a vertical downriver gas duct
and rear gas duct extending enclosure wall forms a section of horizontal gas duct.
3.1.3.1.2 Superheater steam temperature regulation
Superheater attemperators are arranged in two stages with quantity of four (4). The first stage
7
is arranged on connection pipe between vertical low temperature superheater outlet header and
splitter plate inlet header with each on left and right respectively. The second stage is arranged on
connection pipe between vertical superheater rear plate header and final stage inlet header also
with each on left and right respectively.
3.1.3.2 Technical specification
3.1.3.2.1 Roof superheater
1 576.5 SA-213T12 472 pieces Furnace roof pipe
2 638 SA-210A1 Rear gas duct roof pipe
3.1.3.2.2 Low temperature superheater
1 Coiled pipe SA-213T12 Horizontal low temperature superheater
576.5
2 6012 SA-210A1 Horizontal low temperature superheater
637 SA-213T12 Vertical low temperature superheater
3.1.3.2.3 Wall enclosure superheater
1 638 SA-210A1 Front enclosure wall
2 638 SA-210A1 Rear enclosure wall
3 638 SA-210A1 Side enclosure wall
4 44.54.5 SA213-T12 Rear gas duct extending side enclosure
wall and bottom enclosure wall
3.1.3.2.4 Splitter panel superheater
No. Specification Material Remark
1 639 SA-213T22
2 516.5 SA-213T22
3 516 SA-213T23 Splitter panel superheater
4 5110 SA-213T22
5 517.5 SA-213TP304H
3.1.3.2.5 Rear panel superheater

1 578 SA-213T22
2 578 SA-213T91
3 5710 SA-213TP347H
4 5110 SA-213T22
Rear panel superheater
5 517.5 SA-213TP347H
6 518 SA-213T23
7 517.5, SA-213T91
8 5112 SA-213T22
8
9 428 SA-213T91
10 639 SA-213T22
11 639 SA-213TP347H
12 517 SA-213TP347H
13 519 SA-213TP347H
3.1.3.2.6 Final stage superheater
1 5711 SA-213T22
2 579 SA-213TP304H
Final stage superheater
3 579 SA-213T23
4 579 SA-213T91
3.1.4 Reheater
Before ignition, open all the drainage valve and exhaust valve on reheater. Before vacuum
condenser, all the drainage valves and exhaust valves opening into air should be closed. Drainage
valves connecting to condenser may be open until turbine is running with load. The reheated
steam flow is: steam exhausted from HP cylinder goes through horizontal pipe groups arranged
foreside of tail shaft and then enters into vertical pipe groups through transitional pipe group and
finally gathers in reheater outlet header and is introduced into reheating steam pipes from left side.
3.1.4.2 Reheater pipe groups
Reheater consists of three main parts: a) final stage reheater; b) reheater front plate; c) wall
type radiation reheater
Final stage reheater lies in horizontal gas duct behind furnace flame fold corner, there are 78
pieces with pipe diameter of63 between hanging pipe behind cooling water wall and cooling
water wall rack pipe and arranged in boiler width with transverse pitch of 254mm.
Reheater front plate lies between superheater rear plate and rear cooling water wall
suspending pipe and at up section of flame fold angle with 52 pipes and pipe diameter of 63 and
are arranged in boiler width with transverse pitch of 381mm.
Wall type radiation reheaters are arranged at cooling water front and side wall near front
wall with height of about 1/3 of furnace height. Front wall radiation reheater has 280 pipes of
60mm and side wall radiation reheater has 292 pipes of 60mm, which are arranged tightly
along cooling water wall surface with pitch of 63.5mm.
Steam flow is as following:
9
English English
Boiler barrel Horizontal low temperature

superheater
Saturation steam Vertical low temperature

superheater
Roof pipe inlet pipe Vertical low temperature

superheater outlet header

Roof pipe First stage attemperator inlet

connection pipe

Roof bypass pipe Superheater first stage

attemperator
Roof outlet header First stage attemperator

outlet connection pipe

Enclosure wall system Splitter plate inlet header

bypass pipe
Rear gas duct roof pipe Superheater splitter plate
Rear gas duct rear wall Splitter plate outlet header

pipe
Rear gas duct rear wall Connection pipe between

down header splitter plate and rear plate

Rear gas duct side wall Rear plate inlet header

down header (rear)

Rear gas duct rear Superheater rear plate

section side wall pipe
Rear gas duct front wall Rear outlet header

pipe
10
Rear gas duct front wall Second stage attemperator
down header inlet connection pipe

Rear gas duct extending Superheater second stage

side wall down header attemperator

Rear gas duct side wall Second stage attemperator

down header (front) outlet connection pipe

Rear gas duct extending Final stage superheater inlet

section side wall pipe header

Rear gas duct front Final stage superheater

section side wall pipe
Rear gas duct side wall Final stage superheater

up header outlet header
Low temperature Superheater outlet guide

superheater inlet pipe
connection pipe
Horizontal low
temperature superheater
inlet header
After work in turbine HP cylinder, steam is introduced into boiler from cold end reheater pipes
and enters into reheater system. Reheater attemperator lies on cold end reheater pipe.
English
Cold wall reheater pipe
Reheater spray water attemperator
Cold section reheater pipe
Wall type reheater inlet header
Front wall radiation reheater
Side wall radiation reheater
Wall type reheater radiation reheater
11
Connection pipe between wall type reheater outlet
header and reheater front plate inlet header
Reheater front plate inlet header
Reheater front plate
Final stage reheater
Final stage reheater outlet header
Reheater outlet guide pipe
3.1.4.3 Reheating steam temperature regulation

The temperature of reheating steam is mainly regulated through burner up and down swinging
with maximum primary air swinging angle of 27 and secondary air of 30. For the requirement
of transitional or emergent working conditions, emergency spraying water attemperator is installed
at inlet pipeline of reheating steam. Attemperator proper includes barrel shell, spraying device and
straight sleeve etc.
3.1.4.4 Technical Specification
1 604 SA-213T12 Front wall radiation reheater
2 604 SA-213T12 Side wall radiation reheater
3 634 SA-213T22
4 634 SA-213T91
5 637 SA-213T91 Rear panel reheater
6 637 SA-213T22
7 634 SA-213TP304H
8 634 SA-213T91
9 634 SA-213TP304H Final stage reheater
637 SA-213TP304H
3.1.5 Economizer
Economizer is to heat up boiler feedwater, which reclaim heat from gas that is leaving from
boiler.
Economizer is installed at down section of gas duct at back end shaft of the boiler with pipe
of515.5; its section in boiler width section consists of 132 horizontal coiled pipes that are in
aligned arrangement. All the coiled pipes come out from inlet header and end at outlet header.
Feedwater enters into inlet guiding pipe of economizer through check valve and motorized
gate valve of economizer, and then enters into coiled pipes through inlet header of economizer.
The water in coiled pipes flows upwards in adverse current to the gas, which is to exchange heat
effectively and mitigate the possibility of stagnancy caused by steam bubble in coiled pipes. After
heated up in economizer, feedwater enters into outlet header of economizer and then enters into
outlet header through water cooling supporting tube and then is introduced into boiler barrel by
outlet guiding pipes.
Economizer recalculating pipe with 11414 and material of SA-210A1 is connecting the end
part of economizer inlet header and cooling water wall down header. When starting the boiler, the
said pipe introduces boiler water into economizer to prevent the water from boiling away. During
12
start, valve on recalculating pipeline must be open until water is supplied continuously.
3.1.5.2 Technical specification and pipe material boundary:
1 516 SA-210C Horizontal pipe group
2 516 12Cr1MoVG BAC Connection pipe, totally 124
pieces
3 515 SA-210C DEF Totally 16 pieces with single pipe
of 5326mm
GHI
Lie at line of 50-53 and 126-129
4 609 12Cr1MoVG Hanging tube
5 11414 SA-210A1 Recalculating pipe
32 Maintenance Items
3.2.1 Major maintenance items
Name Standard item Special item
(1) Repair manhole, check and clean corrosion and dirty inside (1) Change, modify or
drum; repair mass steam-water
separation devices;
(2) Check inner welding line and steam-water separation device;
(2) Dismantle more than
(3) Measure drum slant and curvature;
50% insulation;
1. Drum (4) Check and clean the inner devices such as water level
(3) Drum welding,
indicator connection pipe, pressure meter pipe tie-in, dosing
mending by replacing a
pipe, blowdown pipe, emergency water discharging pipe etc.
damaged part and
(5) Check and clean supporting and suspending frame, top wave
opening holes
plate and perforated plate, calibrate water level indicator;
(6) Dismantle steam-water separation device, clean and repair.
(1) Clean slag and accumulated ash outside the pipes, check (1) Change header;
pipe welding line and film; (2) Change cooling water
wall pipes more than 5%;
(2) Check abrasion, expansion, distortion, damage, gas eroding
and high temperature corrosion, measure thickness of cooling (3) Acid cleaning for
water wall and change a few pipes; cooling water wall pipes
(3) Check the supporting and suspending frames and expansion
2. Cooling
clearance of hook;
water wall and
header (4) Regulate tightening stress of header supporting and
suspending frames;
(5) Check, repair and correct pipes and pipe rows;
(6) Open header hand hole or cut head, check and clean
corrosion, dirty and sediment inside;
(7) Cut pipes for samples.
(1) Clean accumulated ash outside the pipes; (1) Change more than 5%
pipes or dealing with
(2) Check pipe abrasion, expansion, bending, corrosion and
3. Superheater, mass welding points;
distortion, measure wall thickness and creep expansion;
reheater and
(2) Mend by replacing a
header (3) Check and repair pipe supporting and suspending frames,
damaged part or change
pipe clamp and wear resistant devices etc.;
header;
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(4) Check and regulate header supporting and suspending (3) Change more than
frames; 25% pipe supporting
frame and pipe clamp;
(5) Open hand hole or cut head, check corrosion and clean dirty;
(4) Add more than 10%
(6) Measure creep expansion of header pipe section with steam
heating surface.
more than 450, check header pipe socket welding points;
(7) Cut pipe foe samples;
(8) Change a few pipes;
(9) Correct pipe rows;
(10) Check outlet steam guide pipe elbow, steam header welding
lines.
(1) Clean accumulated ash outside the pipes; (1) Dealing with mass
coiled pipes with defects
(2) Check pipe abrasion, distortion, corrosion and change the
or change more than 5%
unqualified pipes and elbows;
pipes.
(3) Repair supporting and suspending frames, pipe clamps and
(2) Economizer acid
wear resistant devices;
4. Economizer cleaning;
and header (4) Check and regulate header supporting frame;
(3) Change whole row
(5) Open hand hole, check corrosion and dirty and clean inside; economizer;
(6) Correct pipe rows; (4) Change header;
(7) Measure pipe creep expansion. (5) Add or reduce more
than 10% heating surface.
(1) Check and repair mixing type attemperator header, inlet (1) Change attemperator
water pipe and change nozzles if necessary; core;
5.Attemperator (2) Take core of surface type attemperator for check or change (2) Change attemperator
attemperator pipes; header or sleeve.
(3) Check and repair suspending and supporting frames.
3.2.2 Minor maintenance items
3.2.2.1 Four pipes maintenance for heating surface
Check abrasion, corrosion, damage, oxidation and creep expansion of all heating surfaces,
repair or change heating surfaces pipes beyond standards.
3.3.2.2 Check all headers, deal with insulation and check header supporting and suspending
frame and expansion indicators.
3.4 Maintenance Process and Methods
3.4.1 Drum maintenance
3.4.1.1 Preparation
3.4.1.1.1 Prepare all the maintenance related technical materials, tools, apparatus and spare
parts.
3.4.1.1.2 Prepare register of personnel entering into drum.
3.4.1.1.3 Prepare qualified work clothes for maintenance and checking personnel.
3.4.1.1.4 Check whether all the safety measures are executed or not.
3.4.1.2 Open manhole
3.4.1.2.1 Pressure inside boiler barrel drops to zero (0) and temperature is lower than 60 and
after boiler water are totally discharged; dismantle the shielding plate of manhole of drum and
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measure and record bolts length of manhole.
3.4.1.2.2 Dismantle bolts of manholes with special spanners and put bolts and nuts in special oil
tank or oil disk to avoid losing.
3.4.1.2.3 Ventilation and cooling should be done for drum and ventilation should adopt natural
ventilation, forcing ventilation for cooling must be prohibited.
3.4.1.3 Check inside
3.4.1.3.1 When temperature is decreased to be lower than 40 by ventilation, maintenance

personnel should set more than two 12V portable lights in boiler barrel and the transformer should
be put outside boiler barrel. When entering into boiler barrel for work, maintenance personnel
should cover the pipe end firstly and then spread rubber plate on bottom of boiler barrel if
necessary.
3.4.1.3.2 Inform chemical, metal supervision and point check personnel to enter into drum to
check drum level, dirty, corrosion and welding defects etc.
3.4.1.3.3 Check whether connections of separator are loosened or not and whether wielding lines
have defects or not.
3.4.1.3.4 Check whether welding lines of the inner components, inner chuck sleeves have
crackles or not, repair welding should be done according to welding process if there is crackle.
3.4.1.4 Clean rust and dirty inside
3.4.1.4.1 Clean the rust on drum inner wall and in interlayer with steel wire brush, hair brush and
emery cloth and take it out of drum.
3.4.1.4.2 Inform chemical personnel to check it until it is qualified, heating and beating is not
allowed.
3.4.1.5 Check steam water separating device
3.4.1.5.1 Check vortex separator, wave plate separator and tightening situation of inner
components; it should be treated immediately if it is found loosened.
3.4.1.5.2 If vortex separator device rusts or dirties seriously, it should be dismantled and taken out
of drum for cleaning.
3.4.1.5.3 Check circulation at steam-water circulation section.
3.4.1.5.4 All the dismantled devices should be recorded in sequence for convenience of
reinstalling.
3.4.1.6 Check pipe holes and sockets
3.4.1.6.1 Clean around the pipe ends and welding lines, macroscopically check and metallographic
examination should be done for welding lines with related personnel.
3.4.1.6.2 Clean all rust and stem in all pipes and bring them out of drum; measures should be
done for prevent impurities from dropping into pipes.
3.4.1.6.3 Check that whether pipe branch damper, angle plate are in fastness or not.
3.4.1.6.4 Part or total examination should be done to vertical, ring welding lines and downcomer
angle welding lines according to the requirements of metal supervision.
3.4.1.7 Level correction
3.4.1.7.1 Correct level with glass pipe connecting vessels and correct levels of all devices and
trays.
3.4.1.8 Reinstalling inner devices
3.4.1.8.1 According to reversal sequence of dismantling, reinstall the inner devices.
3.4.1.8.2 Inform related acceptance personnel to enter into drum for subsection acceptance.
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3.4.1.8.3 Sort and count the goods brought into drum according to records and evacuate pipe hole
covers and stopper.
3.4.1.9 Expansion indicator
3.4.1.9.1 Check expansion indicators and make sure that all parts are with no damage, clean and
wipe the indication plate; change the indication plate if its scale is blurry; make sure that the
fingers have no block and expansion indicator can expand freely and zero position is corrected.
3.4.1.10 Check supporting and suspending frames
3.4.1.10.1 Check contacting conditions of suspender and drum.
3.4.1.10.2 Check for suspender, suspending bolts in macroscopically and examine destruction
and rigidity if necessary. It is required that there is no loosening, crackle and other defects in
suspending frame.
3.4.1.11 Close down manholes
3.4.1.11.1 Before closing down manhole, check the drum once finally; close it after it is confirmed
that there is no carry-over in it.
3.4.1.11.2 Junction surface should be cleaned before closing manhole, clean the junction surface
of manhole in circumference with emery cloth and drawknife. Change manhole sealing ring and
lay on ceruse oil on bolts and nuts.
3.4.1.11.3 Check contact condition of junction surface with feeler gauge after closing manhole.
3.4.1.11.4 After cold state tightening, manhole can be tightened in hot state when pressure
increases to 0.30.5MPa after ignition.
3.4.1.12 Pressure meter
3.4.1.12.1 Check and calibrate drum pressure meter according to requirement, higher grade
precision pressure meter should be adopted if hydraulic test is to be done.
3.4.2 Cooling water wall maintenance
3.4.2.1 Preparation
3.4.2.1.1 Prepare all the necessary materials, tools, measures, temporary fixed lighting and
portable lights.
3.4.2.1.2 When temperature in working area decreases to be lower than 50, inform lifting
personnel to build scaffold or build suspending frame according to requirement. It is required that
scaffold and suspending frame should be in fastness and comply with requirements of Safety
Rules and be accepted by construction principal.
3.4.2.1.3 There is enough temporary fixed lighting in furnace. It is required that inner lighting
facilities are with fine insulation and in fastness.
3.4.2.2 Check cooling water wall appearance
3.4.2.2.1 Clean coke at burner and accumulated slag and ash on cooling water wall surface; check
creep expansion, abrasion, tambour, damage, crackle and corrosion of pipes, especially cooling
water wall near burner, soot blowing holes, manholes and elbow parts, cold ash hopper slant
cooling water wall, gas fold angle upside, horizontal gas duct inner cooling water wall and
suspending pipes at two sides. The checking results should be recorded well.
3.4.2.2.2 Cooling water wall pipes thickness should be measured selectively; selective check
quantity to cooling water wall near burner and soot blower should be added.
3.4.2.2.3 Expansion values of pipes at two sides of burner and suspending pipes at furnace outlet
should be measured with vernier caliper or home-made calipers. Pay attention that accumulated
ash on pipe surfaces should be cleaned before measurement.
3.4.2.2.4 Check whether incline cooling water wall pipes of cold ash hopper are distorted or not,
whether have concave or not and pipes near water sealing slot have corrosion points or not.
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3.4.2.2.5 Check whether cooling water wall fin pieces have crackles or not. Repair welding should
be done if fin piece has crackles.
3.4.2.3 Cutting cooling water wall pipe section for samples
3.4.2.3.1 When taking samples, exact length, position and quantity of cutting pipe should be
confirmed according to appearance checking results and parts designated by metal or chemical
supervision department; the cutting pipe should avoid rigid beam of cooling water wall.
3.4.2.3.2 Check inside and outside positions, dismantle corresponding boiler wall insulation and
build fixed scaffold well.
3.4.2.3.3 Draw a line and take a record at cutting pipe position, cut fin piece, length of which
should be 100mm longer than cutting pipe at up end and down end respectively.
2.4.2.3.4 When cutting sampling pipe, it should not damage the pipe and neighboring ones.
Welding slag should be avoided dropping into pipes when cutting with air cutting, pipe down end
should be closed down immediately with cover after cutting.
3.4.2.3.5 Position, fire disclosure surface and medium flow direction should be marked clearly for
sampling pipe.
3.4.2.4 Cooling water wall pipe section change
3.4.2.4.1 Slopes of two ends of confected new pipe and cooling water wall should be done, inside
and outside pipe wall within 10 mm15mm near welding points should be cleaned and polished
before pipe welding and assembling until metal shine is shown.
3.4.2.4.2 Spectral analysis should be done for new pipes before using; check conditions of ellipse
degree, wall thickness, spectrum, rust and damage of bending parts.
3.4.2.4.3 Argon welding rendering should be adopted or full argon welding should be adopted.
3.4.2.4.4 After welding, contact with metal to have examination and record well; after qualification,
weld the fin piece and recover pipe rows.
3.4.2.5 Supporting and suspending frames check
3.4.2.5.1 Check tightening stress of all the suspender, suspending frame and suspender bolts on
roof the boiler.
3.4.2.5.2 Check suspender spring.
3.4.3 Superheater maintenance
3.4.3.1 Superheater pipes appearance check
3.4.3.1.1 Prepare all the tools, apparatus and materials for changing before construction.
personnel to build scaffold, which should be checked and accepted by construction principle.
3.4.3.1.3 Start an IDF, clean along gas duct in gas flow direction from front to rear with
compressed air.
3.4.3.1.4 Check conditions of creep expansion, abrasion, tambour, damage, crackle and corrosion
of pipes and take records well.
3.4.3.2 Cutting pipe of superheater
3.4.3.2.1 Report the pipe surface checking results to equipment department, metal and chemical
supervision personnel and then decide part, dimension and quantity of cutting pipe according to
requirement. The distance between cutting point and elbow starting point or header wall should be
at least more than 100mm; distance between two welding points should be more than 200mm.
3.4.3.2.2 Draw a line before cutting pipe, mechanical method must be adopted for cutting, special
personnel should be sent to supervise to avoid damaging other pipes; if pipe cut can not be
recovered in a short time, temporary blocks should be added and seal should be used on to avoid
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impurities.
3.4.3.2.3 Confect new pipe section according to cutting pipe dimension, metal spectral analysis
must be done for new pipe and metal spectral analysis report should be formed.
3.4.3.2.4 Check the welding points, unqualified welding points should be welded again.
3.4.3.2.5 Heat treatment should be done for alloy steel pipes according to regulation requirement
before and after welding.
3.4.3.3 Checking fixed block and suspending frame
3.4.3.3.1 Check abrasion condition of suspending hoop, suspending block, fixing splint and fixing
block, change or repair welding according to actual condition.
3.4.3.3.2 Check the fixing clamps are straight or not and pipe rows are smooth or not; correct them
if not.
3.4.3.3.3 Clean accumulated ash and impurities at bottom of down elbow to avoid blocking
channels.
3.4.3.3.4 Check all wear resistant devices and repair or change according to actual condition.
3.4.4 Reheater maintenance
3.4.4.1 Checking appearance of reheater pipes
3.4.4.1.1 Prepare all the tools, apparatus and materials for changing before construction.
personnel to build scaffold, which should be checked and accepted by construction principle.
3.4.4.1.3 Cleaning method for reheater heating surface is the same with method for superheater. It
is required that there should no accumulated ash on pipe wall of superheater after cleaning.
3.4.4.1.4 Check conditions of creep expansion, abrasion, tambour, double skin, crackle and
corrosion of pipes and take records well.
3.4.4.2 Cutting pipe of reheater for sample
3.4.4.2.1 Report the pipe surface checking results to equipment department, metal and chemical
supervision personnel and then decide part, dimension and quantity of cutting pipe according to
requirement. The distance between cutting point and elbow starting point or header wall should be
at least more than 100mm; distance between two welding points should be more than 200mm.
3.4.4.2.2 Draw a line before cutting pipe, mechanical method must be adopted for cutting, special
personnel should be sent to supervise to avoid damaging other pipes; if pipe cut can not be
recovered in a short time, temporary blocks should be added and seal should be used on to avoid
impurities.
3.4.4.2.3 Confect new pipe section according to cutting pipe dimension.
3.4.4.2.4 Check the welding points, unqualified welding points should be welded again.
3.4.4.2.5 Heat treatment for welding points required heat treatment must be done according to
regulation requirements.
3.4.4.3 Checking fixed block and suspending frame
3.4.4.3.1 Check burning condition of suspending hoop, suspending block, fixing splint and fixing
block, change or repair welding according to actual condition.
3.4.4.3.2 Check the fixing clamps are straight or not and pipe rows are smooth or not; correct them
if not.
3.4.4.3.3 Clean accumulated ash and impurities at bottom of down elbow to avoid blocking
channels.
3.4.4.3.4 Check and repair all wear resistant devices, wear resistant tiles that in reversal and
knobs should be changed with new ones and welding should be done by special welder.
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3.4.5 Economizer maintenance
3.4.5.1 Ash cleaning of economizer
3.4.5.1.1 When cleaning ash in pipe rows of economizer, start an IDF to keep a certain negative
pressure in furnace and gas duct.
3.4.5.1.2 Clean the accumulated ash on pipe surface and pipe clamp from above to below.
3.4.5.1.3 Clean and dredge accumulated ash in ash hopper of economizer.
3.4.5.2 Checking economizer appearance
3.4.5.2.1 Measure the wall thickness of straight pipe section between two sides of pipe clip and
elbow of the first pipe (along with gas flow direction) of up and down pipe row, of pipes around
blower pipe within purging journey of soot blower, of pipes and elbows of easy abrasion part of
suspending pipes near pipe rows.
3.4.5.2.2 Check pipes at other parts that whether they have defects such as corrosion, abrasion,
tambour or color changing etc., wear resistant tile should be added for serious abrasion part.
3.4.5.2.3 Check supporting and holding devices of economizer. Pipe rows should be complete and
pipe clips are in fastness. Clearance between pipe rows and transverse pitch is even with error of
no more than 5mm, individual pipe bending should not be more than 20mm. Clean the impurities
between pipe rows.
3.4.5.2.4 Check and regulate wear resistant device, dropped and damaged wear resistant tiles
should be changed and inclined and distorted wear resistant tiles should be fixed.
3.4.5.2.5 Check economizer header.
3.4.5.3 Cutting pipe for sample
3.4.5.3.1 Cutting position, quantity and dimension of sampling pipe should be confirmed by
chemical supervision personnel and cutting position of sampling pipe should be recorded.
3.4.5.3.2 Cut sampling pipe section with mechanical method and record it well with row number
and section and it should be sent to chemical and metal department for checking; if pipe cut can
not be recovered in a short time, temporary blocks should be added and seal should be used on to
avoid impurities.
3.4.5.3.3 Confect new pipe and weld according to cutting pipe position, metal inspection should be
qualified after welding.
3.4.5.3.4 Recover suspending frame clips and wear resistant devices.
3.4.5.4 Urgent repair for economizer pipe leakage
3.4.5.4.1 After boiler stops and pressure is released, gas duct should be kept in ventilation; keep
the water in economizer.
3.4.5.4.2 After temperature in gas duct decreases to be within permit range, enter into gas duct
and look for the leaking points confirm the right leaking parts according to water mark, sound and
accumulated ash of pipe rows.
3.4.5.4.3 After confirming leaking position, inform the operators to completely discharge water and
isolate economizer system.
3.4.5.4.4 During maintenance, different methods can be adopted according to specific leaking
positions.
3.4.5.4.5 For the pipe section that gets thinner due to blowing, if abraded area is less than 10mm
and abraded pipe wall is less than 30% of designed pipe thickness, repair welding can be done for
it.
3.4.5.4.6 Before cutting pipe, accumulated ash on pipe rows around should be cleaned and clean
the accumulated ash in ash hopper after welding.
3.4.5.4.7 Clean all the impurities within maintenance area in boiler.
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3.4.5.5 Checking economizer header
3.4.5.5.1 It should be decided whether to check the inner part of economizer header or not
according to the requirements of boiler and chemical supervision personnel.
3.4.5.5.2 After cutting header hand holes, inform boiler supervision and chemical supervision
personnel to check it.
3.4.5.5.3 If the cut hand hole can not be recovered in a short time, temporary blocks should be
added and seal should be used on to avoid impurities.
3.4.5.5.4 Clean the impurities, dirties in the header and make hand hole cover and pipe cover.
3.4.5.5.5 Recover hand holes cover and metal inspection should be qualified.
3.4.6 Attemperator maintenance
3.4.6.1 Common check
3.4.6.1.1 Check welding lines at all parts of attemperator header.
3.4.6.1.2 Check whether firm bolts are dropped or loosened or not.
3.4.6.1.3 Check header suspending and supporting frames.
3.4.6.1.4 Macroscopically checking for header.
3.4.6.2 Inside checking for superheater attemperator
3.4.6.2.1 Cut the transitional pipe of attemperator and take flute pipe for checking.
3.4.6.2.2 Check whether there is cracks, distortion or abrasion of flute pipe or not and, water
spraying holes are blocked by accumulated dirty or not.
3.4.6.2.3 Check inner wall of sleeve pipe inside header.
3.4.6.2.4 Reinstall flute pipe and weld transitional pipe connection.
3.4.6.3 Inside checking of reheater attemperator
3.4.6.3.1 Take out nozzles.
3.4.6.3.2 Check nozzles aperture and welding line.
3.4.6.3.3 Check inner wall of sleeve pipe insider header.
3.4.6.3.4 Reinstall nozzles.
3.5 Maintenance Quality Standard
3.5.1 Drum maintenance quality standard
3.5.1.1 Portable light with voltage more than 12V is not allowed to be used in drum.
3.5.1.2 Personnel and goods entering into drum must be registered and special person supervise
it outside of the drum.
3.5.1.3 All the welding lines have no defect and repair welding should be done strictly according to
welding process.
3.5.1.4 There is no floating rust in drum.
3.5.1.5 Black and red protection film should not be cleaned out when ridding up drum wall.
3.5.1.6 There is no dirty and corrosion in separator and connection pipes.
3.5.1.7 Welding line of pipe aperture and pipe socket have no defects, stem is cleaned up;
supporting damper and angle plate are in fastness.
3.5.1.8 Devices in drum are rightly installed and complete and in fastness, no foreign goods is
allowed to left behind.
3.5.1.9 Indication plate and indication finger of expansion indicator are right and in fastness; the
surface of indication plate is clean with clear scale, indication finger is corrected to zero position.
20
3.5.1.10 Suspender and drum contact well with sufficient interface, suspender and suspending
bolts are in even force with no eroded appearance.
3.5.1.11 Junction surface interface are fine after manhole is closed, tight bolt of manhole is in even
force and bolt extending length should be recorded.
3.5.1.12 Ensure that pressure meters are complete and precise.
3.5.2 Cooling water wall maintenance quality standard
3.5.2.1 Check abrasion of creep expansion and check fire disclosure surface with calipers or
thickness measuring instruments, records should be taken well.
3.5.2.2 Pipe with creep expansion exceeds 3.5% of original diameter should be changed.
3.5.2.3 Pipe with part abrasion exceeding 20% of original pipe thickness should be changed;
repair welding should be done for pipe with abrasion not exceeding 20%.
3.5.2.4 Slope cooling water wall pipes of cold ash hopper have no distortion and concave, depth of
pipe corrosion points should be no lea than 30% of pipe wall thickness.
3.5.2.5 Welding lines of cooling water wall fin have no crackles and no distortion and are smooth.
3.5.2.6 Dismantle furnace insulation as per dimension by adding 200250 to cutting pipe figure.
3.5.2.7 Fin piece welding line cutting length should be cut as per length of 50mm longer at each
end than sampling pipe.
3.5.2.8 Pipe cutting position should be right and pipe cut should be 200mm away from original
welding point.
3.5.2.9 Related regulations should be strictly executed during pipe machining and welding.
3.5.2.10 Welding should be done by qualified HP welder.
3.5.2.11 Strong counterparts are prohibited.
3.5.2.12 There is no crackle or edge-biting on fin pieces after welding.
3.5.2.13 All the suspenders and suspending frames on boiler roof are complete with no bending or
incline, suspender nuts are not loosened and in even force.
3.5.2.14 There is no overheating, oxidation, elongation or distortion for suspender.
3.5.2.15 Suspender spring should be complete with no corrosion or block.
3.5.3 Superheater and reheater maintenance quality standard
3.5.3.1 Check creep expansion abrasion, and measure the outer pipe in every row with calipers
and take records.
3.5.3.2 Alloy pipe with creep expansion exceeding 2.5% of original diameter should be changed.
3.5.3.3 Pipe with part abrasion exceeds 1/3 of original thickness and area exceeding 10cm2 should
be changed and repair welding should be done for pipe not exceeding standard.
3.5.3.4 Pipe configuration and mouth matching should be done according to related regulations.
3.5.3.5 Clips and blocks should be recovered to be complete according to manufactures
requirements.
3.5.3.6 Chemical and metal check is qualified.
3.5.3.7 Pipes are arranged in order, pipe row stands out and pipe section should be 20mm less
than center line.
3.5.3.8 There is no accumulated ash in bottom of elbow.
3.5.3.9 Screw caps of suspending and supporting frame are not loosened; suspending and
supporting frame and welding line have no crackles.
3.5.3.10 Wear resistant device are complete and in fastness.
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3.5.4 Economizer maintenance quality standard
3.5.4.1 There is no accumulated ash on surface of economizer surfaces and no impurities
between pipe rows; ash hopper is smooth with no accumulated ash.
3.5.4.2 Pipes abraded thickness should be less than 30% of original pipe wall thickness.
3.5.4.3 Pipe with expansion value exceeding 3.5% of original pipe diameter should be changed.
3.5.4.4 Pipe and header appearance has no damage, corrosion or other defects.
3.5.4.5 Pipe rows are smooth, transverse pitch is even and pipe clamp has no distortion.
3.5.4.6 Pipe section configuration and welding should comply with related regulations.
3.5.4.7 Suspending frame, clip and wear resistant devices are complete.
3.5.4.8 There is no accumulated dirty, rust or impurities in headers.
3.5.4.9 After checked and confirmed to be qualified by chemical and boiler supervision personnel,
welding should be done by HP welder with certificate.
3.5.4.10 Metal inspections should be qualified.
3.5.6 Attemperator maintenance quality standard
3.5.6.1 Welding line has no defects or has no defects after treatment.
3.5.6.2 Tight bolts are in fastness and with no dropping.
3.5.6.3 Suspending and supporting frames are complete and in even force.
3.5.6.4 Bending degree of header should not exceed 4mm per meter.
3.5.6.5 Spiracles are complete with no distortion, block, corrosion or crackles. Eyelet erosion
should not be 30% bigger than original diameter.
3.5.6.6 Inner sleeve pipe of header has no defects such as erosion and crackle.
3.5.6.7 Nozzles have no block and aperture changing rate should be less than 5%, welding lines of
nozzles have no crackles.
3.5.6.8 Attemperator inner sleeve pipe surface has no crackles and corrosion.
3.5.6.9 Nozzles direction should be right after reinstalling and with no leakage.
. Safety, Health and Environmental Protection Requirements

4.1 Safety
4.1.1 Workers working in high altitude should be careful and safety belt should be tied to reliable
place; spare parts, materials, tools and apparatus should be put at reliable places.
4.1.2 Voltage of portable lighting should be lower than safe voltage of 36V, fixed lighting should be
reliable. Check whether wires have dilapidation or naked parts or not. Working personnel should
wear insulated shoes.
4.1.3 All the tools and apparatus should be strictly checked with no defect before using.
4.1.4 Working personnel should wear work clothes with tight sleeves according to regulations; fire
proof isolation measures should be done when welding on scaffold, safety net and wooden spring
board.
4.1.5 Working personnel should wear protection glasses when using polishing tools.
4.1.6 Before starting work, check the scaffold, suspending frame carefully, and work only can be
started after it is confirmed that there is no danger.
4.1.7 When working in gas duct at tail section of the boiler, materials, spare parts, tools and
apparatus that may drop from gaps of pipe rows should be put on asbestos wooden plate or
rubber to prevent from dropping.
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4.1.8 Check the safety measures with operators before starting work, check whether power supply
of rotating machine is but off or not and all the air dampers should be strictly closed.
4.1.9 Before using air-driven tools, check whether air cylinders leak due to aging, especially the
connections should be in tight colligation; working personnel should wear protection glasses.
4.2 Health
4.2.1 When working in boiler or places with much gas or dust, working personnel should wear
dustproof protective masks.
4.2.2 Ash and dust after burning in boiler is harmful to health, clean immediately after work is
completed.
4.2.3 When working in condition of high working environment temperature, measures preventing
siriasis should be done.
4.2.4 Protections should be done when contacting with silicic acid aluminium that is pungent to
skin.
4.3 Environment
4.3.1 When cleaning, please do not sweep dust from high places to avoid environment pollution.
4.3.2 When dismantling heat insulation of equipments, the dismantled heat insulation should be
reserved to prevent from scattered on grid plates.
4.3.3 Clean the site after work is completed and keeps working site clean.
5. Twenty five Important Anti-Accident Measures
5.1 During maintenance of heating surface, measures should be taken to prevent foreign materials
such as tools, welding slag entering into boiler pipe, which may cause block and results in pipe
explosion due to overheating of heating surface.
5.2 During maintenance period, all the temperature detection points of heating surface should be
checked to prevent wall temperature error due to detection points dropping.
5.3 If the unit stops or water quality is not qualified for a long time, maintenance items should be
properly extended and items of cutting pipes for samples should be added to check whether there
is corrosion on heating surface or not.
5.4 During unit maintenance check connections in four corners of rigid beam of cooling water wall
and suspending framework of burner carefully, treat it in time if any problem is found. Avoid cooling
water wall leakage due to cooling water wall or overload at welding line of burner and cooling
water wall fin.
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Chapter Maintenance Regulation for Pipes and Valves of the Boiler
. General
1.1 Applicable scope: this chapter is applicable to boiler pipes and valves part of Indonesia Paiton
1660MW coal fired thermal power plant.
1.2 Quoted material:
Daishan Power Plant Boiler Maintenance Regulation
Twenty five Key Requirements on Prevention of Major Accidents Requirements in Electric
Power Generation
Guide of Maintenance of Boiler Unit for Thermal Power Plant DL/T 748.2
The Code of erection and acceptance of electric power construction Section of Welding of
Thermal Power Plant DL50071992
Technical Supervision Codes for Metal in Thermal Power Plants DL 4382000
VELAN Valve Maintenance Manual
Dresser Safety Valve Maintenance Manual
Supervision Code for Boiler and Pressure Vessel of the Power Industry DL6121996
Inspection Code for Boiler and Pressure Vessel of the Power Industry DL6471998
Technical Supervision Code for Metal in Thermal Power Plants DL43891

Code of Safety Operation in Power Industrial (Thermal and Mechanical Part) 1994 Edition
. Equipment Brief Introduction and Parameters

2.1 Main equipment system
Boiler valves
Safety valve and power control valve of drum, superheater and reheater, attemperating
regulation valve of superheated steam and reheated steam; motor-driven gate valve and check
valve of feedwater pipeline, regulation valve and motor-driven valve of feedwater bypass; outlet
valve of boiler water circulating pump; boiler blowdown valve, HP drainage valve, motor-driven
gate valve, check valve, block valve for hydraulic test of reheater inlet and outlet and valves in fuel
oil system. Stop valve, regulation valve, safety valve and accessories in equipment, steam, water,
oil and air systems of boiler and that necessary for safety and reliable operation and maintenance
of the power plant.
Boiler adopts feeding water in single pipeline; the feedwater pipeline from feedwater
operation platform to economizer inlet is laid by design institute. Main feedwater pipeline
specification is 508X40mm with material of 15NiCuMoNb5-6-4; motor-driven gate valve and
check valve are set on main feedwater pipeline. Feedwater bypass is set for feedwater
platform, its pipeline specification is 27325mm and its material is 15NiCuMoNb5-6-4.
Bypass motor-driven regulation valve is set for the pipeline and motor-driven gate valves are
set before and after motor-driven regulation valve. Transitional section of same material with
pipeline is welded at two ends of valves when above valves leave factory. Feedwater is
introduced into economizer inlet header at right underside of boiler tail vertical shaft from boiler
left side single line after passing through operation platform.
Arrangement diagram of feedwater control console is as following:
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According to ASME requirement, at least one glass water level indicator and two water
level indication device with signs of alarm and trip should be installed for each boiler. Two
double color water indicators are installed with each one at left and right side of boiler barrel,
five single room balancing vessels, water level automatic protectors, water regulator and disc
water level indicators are also installed for boiler barrel. A full water balancing vessel is also set
on boiler barrel, upper end of which barrel eduction pipe tie-in is installed and lower end of
which upper tie-in of balancing vessel is installed. Industrial television system equipped for
double-color water level indicators adopts two sets of local camera systems and one
monitoring system (two in front and one at back). Two local pressure meters with one for
continuous blowdown and one for dosing respectively and two tie-ins on saturation steam
sampling pipe are installed on boiler barrel. One check valve and one non-return valve are
installed on dosing pipeline; one check valve and one angle type motor-driven regulation valve
are installed on continuous blowdown pipeline. Six spring safety valves are installed at head
cover of boiler barrel, their total discharge capacity is 89.56 BMCR (Boiler Maximum
Continuous Rating). It should be comply with ASME code and requirements of standard
regulations.
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English English
Boiler accessories Balance vessel
Double color water

Pressure pulse
level indicator
Connect to down Local pressure

comers meter
Safety valve Pressure signal
Drain water Boiler water
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sampling
Continuous
Air discharging
blowdown
Saturated steam
Nitrogen charging
sampling
Local full water
Nitrogen charging
balance vessel
Balance
vessel(water level
Air discharging
automatic
protection)
Double colour
Balance vessel water level
indicator
Saturated steam Connect to down

sampling comers
Salt detector Drain water
Balance vessel Safety valve
Local pressure
dosing
meter
Pressure signal Barrel
Balance vessel
Drainage valve and backwash (acid cleaning) tie-in should be installed at bottom of
downcomers, drainage water of which is generally is taken as drainage water of boiler
shutdown. Boiler periodic blowdown is set at bottom of four downcomers that is educed by tee
and gathered to discharging water distribution header through guide pipe; if it is taken as boiler
discharging water, the boiler steam pressure must be lower than 5.17MPa (750psi). Drainage
valve and boiler periodic blowdown valve are installed on distribution header; see as in
following arrangement diagram.
27
English English
Central down comer

accessories Central down comer
arrangement diagram
To distribution box of
Distribution box
water discharging
Backwash(acid
Drainage water
cleaning)
Periodic blowdown Drainage water
Blowdown
Blowdown is a way to control boiler water concentration () and discharge sediment of mud.
Blowdown times depends on specific working condition of the boiler, such as water quality
characteristics, water treatment effect, boiler design characteristic and output etc. Continuous
blowdown on boiler barrel is enough under most of conditions.
If special working condition that mud sediment is produced, water treatment effect is not
good or salinity content is high, blowdown can be done through periodic blowdown pipeline of rear
water cooling wall down header. Generally, periodic blowdown should be done once per shift or
once per 24 hours, specific condition may be confirmed according to water quality.
DN125 water discharge valve is installed on boiler front water cooling wall down header and
is only used for discharging water after boiler shutdown but not emergency discharge under
normal condition or blowdown neither.
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Check valve is installed at enclosure wall down header for drainage water and 5% startup
drainage water bypass is set on rear enclosure wall down header. 5% startup drainage water
bypass generally does not work as startup bypass but as rear enclosure wall drainage water
because there is turbine bypass system in this project.
Two (2) spring safety valves with model of HCI-88W 3 M2 6 are installed on outlet pipeline
of second stage superheater, total discharge amount of superheater safety valves and barrel
safety valves is 106.00BMCR. Four (4) power control release valves with model of
EOL121N7BWRA5P1 2.54 are installed on main steam pipeline and discharge amount of each
valve is 2%, which complies with requirements of ASME rules and B&W standard regulations.
Two (2) spring safety valves with model of HCI-38W 6 R 8 are installed on outlet pipeline of
reheater, total discharge amount of the two safety valves is 8% of reheater maximum steam flow,
which complies with requirements of ASME rules and B&W standard regulations. Primary valve,
thermocouple socket and tie-ins of local pressure meter, pressure signal and steam sampling are
also installed on outlet pipeline of reheater.
Seven (7) spring safety valves with six of model of HCI-46W 6 R 8 and one of model of
HCI-46W 6 RR 10 are installed on inlet pipeline of reheater, total discharge amount of the safety
valves in reheater system 101.17% of reheater maximum steam flow, which complies with
requirements of ASME rules and B&W standard regulations.
Hydraulic test should be done for reheater separately after boiler installation; thus, a set of
block plates should be arranged on inlet & outlet pipeline of reheater.
DN32 deflation check valve and DN32 charging nitrogen check valve are installed on pipeline
from boiler barrel and economizer outlet header to boiler barrel, inlet & outlet header of panel
superheater and outlet header of reheater. It is recommended to discharge water out from boiler
proper with nitrogen after hydraulic test. During protection period after boiler shutdown, it is
recommended to charge nitrogen to protect drainage water parts to avoid rust on heating surface.
DN50 self steam tie-in for boiler soot blowing steam is set on outlet header of panel
superheater, where a P5517, DN50 check valve is set connecting to soot blowing pipeline.
Two stage spraying water attmperating devices are installed to control superheating steam
temperature by regulating spray water amount to mix high temperature steam and low
temperature water to get required steam temperature. Spraying water comes from feedwater
system and is educed from HP reheater front to nozzles through pipeline. The first stage spraying
water attemperator is arranged on connection pipeline between first stage superheater and inlet
header of panel superheater with each one at left and right respectively. Spraying water pipeline is
designed by design institute and our company in cooperation, specification of general pipe
connecting to pipe designed by institute is 61065mm/3030 mm, pipeline specification of first
stage spraying water is 440X5/22mm/2480 mm. CL.2500#, 3 motor-driven regulation valves are
also set with structure characteristic of equal percentage. CL.2500#, 6 motor-driven regulation
valves are set before and after regulation valve. Attemperator is Venturi type.
Second stage spraying water attemperators are also Venturi type and arranged on connection
pipeline between panel superheater outlet header and second stage superheater inlet header with
each one at left and right respectively. Specification of general pipe connecting to pipe designed
by institute is 61098mm/L3030 mm, spraying water pipeline specification370X10/L2494 mm.
CL.2500#, 3 Specification of motor-driven regulation valve is CL.2500#, 3 with sturcuture
characteristic of equal percentage. CL.2500#, 6 motor-driven regulation valves are set before and
after regulation valve.
As per design requirements: first stage attmperating water amount is controlled by minimum
permit steam temperature of steam entering into panel superheater header. When first stage
spraying water amount can not meet requirement and it is necessary to regulate steam
temperature slightly, the second stage spraying water attemperator should be adopted to control.
Reheater spraying water attemperator is arranged on extended pipe section of reheater inlet;
it is only used as emergency spraying water under emergency working condition when there is no
requirement for water spraying under normal condition.
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Recalculating pipe of 133X16mm is arranged between downcomer and economizer inlet
header, 2500#, 6" motor-driven gate valve is installed on the pipeline.
Sampling tie-in for feedwater, boiler water and saturation steam are respectively installed
on feedwater pipeline, continuous blowdown pipeline and boiler barrel to monitor quality of
feewwater, boiler water and steam.
Safety valves are the product of America DRESSER Company, imported motor-driven
regulation valves are product of America FLOWSERVEVALTEK Company, imported shut-off
valve are of Canada VELAN Company, imported shut-off valves of instrumental meters
pipeline are of America CONVAL Company and home-made valves are of Hangzhou Huahui
Valve Co., Ltd.
. Maintenance Items
3.1 Major maintenance items
Maintenance of safety valve and solenoid relief valve
1 Primary steam safety valve dismantling and repair
2 Secondary steam safety valve dismantling and repair
3 Reheater Vent steam exhaust valve dismantling and repair
4 Drum safety valve dismantling repair
5 Solenoid blowout valve dismantling repair
6 Gate valve before solenoid blowout valve dismantling repair
7 Solenoid blowout bypass valve repair
8 Solenoid blowout signal valve dismantling and repair
9 All pipeline of safety valves and water skip repair
10 Suspending and supporting frames of safety valve pipeline repair
11 Metallographic inspection for bolts and nuts of safety valves
12 Repair for drive devices of all valves in system
13 Safety valve pressure setting
Feedwater System
1 Non-return valve dismantling and repair
2 Check valve dismantling and repair
3 Economizer water discharge primary and secondary valve dismantling and repair
4 Economizer recalculating valve repair
5 Main feedwater pipeline air valve repair
6 Feedwater flow orifice plate repair
7 Transmitter and flow meter primary valve dismantling and repair
8 Check suspending and supporting frames of pipes
Steam system
1 All valves dismantling and repair in the system
2 Check welding lines of pipelines (according to metal requirements)
3 Check and measure creepage of main steam pipeline
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4 Check and measure creepage of reheating pipeline
5 Reheater hydraulic test repair
7 Repair for manhole before reheater hydraulic test valve
8 Repair for primary valves of pressure meters and transmitters
9 Repair for all thermocouples at all parts
10 Temperature socket repair
11 Dismantling and repair of primary and secondary air valves of all pipelines
12 Check suspending and supporting frames of pipelines
Attemperating water system maintenance
1 Repair of regulation valves above Dg100
2 Repair of lock valves above Dg100
3 Repair of regulation valves under Dg100
4 Repair of lock valves under Dg100
5 Repair of attemperating water motor-driven valves above Dg100
6 Repair of attemperating water motor-driven valves under Dg100
7 Repair of valves above Dg32
8 Repair of valves under Dg32
9 Repair of drive actuator of valve
10 Attemperating water flow orifice plate repair
11 Atemperating water temperature socket repair
12 Pipeline suspending and supporting frame repair
Drainage water, deflation system
4 Repair of all water discharging pipelines and funnels
5 Repair of drive devices of all valves
Dismantle and repair of all valves in sampling system
Continuous blowdown, dosing system maintenance
1 Dismantle and repair all valves in system
Water gauge repair
1 Water gauge dismantling and repair
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2 Repair of steam water primary and secondary valve of water gauge
3 Repair of drainage valve of water gauge
Nitrogen charging system
1 Repair all valve in the system
2 Repair pipelines, suspending and supporting frames
3 Welder working time
3.2 Minor overhaul
Dismantle and repair safety valves with inner leakage
Attemperating water system repair
Water level indicator repair
1 Dismantle and repair water level indicator
2 Repair steam water primary and secondary valves of water level indicator
3 Repair drainage water valve of water level indicator
Defects of valves in operation
. Maintenance Process and Process Methods

4.1. VELAN check valve maintenance process
4.1.1 Preparation
4.1.1.1 Confirm that there is no pressure in valve and pipeline connecting to it.
4.1.1.2 Prepare ground for dismantling and assembling valve, parts should not be damaged when
piling up.
4.1.1.3 Prepare all necessary tools and measures.
4.1.1.4 Prepare calipers and do mapping for valves after dismantling, records should be well
taken.
4.1.2 Valve dismantling
4.1.2.1 Marks should be made at flange connections before dismantling valve, waggle valve for
several rings with hand wheel. Loosen link bolts of gland packing gland pressing cover and loosen
stuffing pressing cover pressing plate. Special standard spanner should be adopted when
loosening pressing cover nuts of gland packing.
4.1.2.2 Take of electric-driven device of motor-driven valve. Drive head should be put in level after
taking off to avoid gear oil in worm wheel box leaking into motor.
4.1.2.3 Dismantle valve frame
A For check valves connecting bolts, unfold stop gasket and loosen fixing bolts of frame.
B For the valves connected by screw threads, sawing or picking should be adopted to remove
welding point. Connecting screw threads of frame and valve can not be damaged during sawing or
picking.
C Turn the frame anticlockwise and the upper valve stem in open direction to make lower
stem rise together, take off frame together with upper and lower valve stem. After taking off frame,
valve body should be well sealed with seal to avoid impurities dropping into it.
4.1.2.4 Frame dismantling
A For the check valve Dg10 and Dg20, loosen the two connection nuts, take off bolts, take out
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ball bearing and lower valve stem. Check valve Dg20 has connection gasket. Screw out upper
stem from stem nut.
B For check valves Dg40, Dg50 and Dg65, loosen openness indication plate. Take out lower
stem and connection pin of connection sleeve with punch, take out valve stem and connection
steel ball. Preserve them well.
C Screw out upper valve stem from stem nut. Retreat ball bearing from holes on connection
sleeve and make connection sleeve separate from valve stem. Preserve ball bearing well.
3.4.1.2.5 Clean sealing stuffing, take off stuffing pressing cover and pressing plate from lower
valve stem, clean and grind stuffing seat ring. Measure all dimension of pressing cover, seat ring,
valve stem and stuffing box.
4.1.3 Check and repair
4.1.3.1 Check valve body.
4.1.3.2 Check valve stem.
4.1.3.3 Check sealing surface.
4.1.3.4 Check bolts and nuts.
4.1.3.5 Check clearance.
4.1.4 Valve assembling
4.1.4.1 Clean inside of valve body.
4.1.4.2 Screw on upper valve stem into nuts on valve frame.
4.1.4.3 For valves Dg10 and Dg20, clean lower valve stem and slip into stuffing seat ring and then
put it into frame, stuffing pressing cover and pressing plate should be put between two sections of
valve stems. Connect upper and lower stem with connection plate, and put ball bearing (Dg10
valve) and gasket (Dg20 valve) between valve stems.
4.1.4.4 For valves Dg40, Dg50 and Dg65, slip connection sleeve onto valve stem and install ball
bearing from hole of connection sleeve. Lay down valve stem, clean it and then put it into frame;
stuffing pressing cover and pressing plate should be put between two sections of valve stems. Put
ball bearing between upper and lower ball bearing, pull on lower stem into connection sleeve and
fix it with pin. Tight openness indication plates on connection sleeve.
4.1.4.5 Slip valve frame onto valve body and turn it clockwise to bottom of valve body. For valves
Dg40, Dg50 and Dg65, fixing bolts should be used to fix valve body and frame and stop gasket
should also be installed.
4.1.4.6 Stuff gland packing.
4.1.4.7 Press stuffing tightly with stuffing cover by using link bolts and pressing plate to ensure a
sound sealing.
4.1.4.8 Install hand wheel, connection stem and electric-driven devices.
4.1.4.9 Operation valve is at close state. Hang signs of valve well and clean the site.
4.1.4.10 Operators should check equipment environment and accept it after it is qualified.
Conclude the work permit ticket.
4.1.5 Hydraulic test
4.1.5.1 Before operation, hydraulic test of the equipment should be done together with the boiler.
Check whether there is water leakage at gland packing or not. Medium flows out from outlet of
pipeline when valve is open and there is leakage after it is closed, which shows that sealing
surface of valve is qualified and gland packing is properly filled.
4.2 Safety valve overhaul
4.2.1 Safety valve dismantling
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4.2.1.1 Confirm positions of upper and lower regulation rings and take records well.
4.2.1.2 Open cotter pin at upper section and dismantle manual startup device and spring cover.
4.2.1.3 Measure and regulate screw threads height and take records well.
4.2.1.4 Demount bolts on spring seat and loosen regulation bolts (at this time, spring is pressing
tightly on spring cover). Demount three connection nuts of spring cover and cooler in symmetric
position and screw down two long bolts on the cross and then demount all the other bolts, and
then loosen the two long bolts evenly to avoid distortion of valve stem due to beading moment until
the springs are in free state.
4.2.1.5 Demount spring cover, spring and spring seat and put them on designate location.
4.2.1.6 Demount steam exhaust pipe and then loosen nuts connecting cooler and valve body,
demount cooler.
4.2.1.7 Take out valve stem and suspend it vertically on special shelf with iron wire to avoid
distortion.
4.2.1.8 Measure and record positions of upper and lower regulation rings.
4.2.2 Safety valve check
4.2.2.1 Demount pressing cover nuts, lining sleeve, upper and lower regulation stems, check
whether screw threads are free from damage or not, it should be repaired with file if there is. Clean
it with 1755 detergent after removing rust.
4.2.2.2 Take out upper and lower regulation rings, clean screw threads completely.
4.2.2.3 Check whether valve seat surface has defect or not, whether there is thickness decreasing
phenomenon caused by abrasion and erosion or not.
4.2.2.4 Measure penetrating welding metal thickness of sealing furnace and nonparallelism of
nozzle type valve seat sealing surface and upper cut of valve body, if they exceed standard,
sealing surface should be grinded and aligned (penetrating welding metal thickness should not be
less than 4mm, nonparallelism of nozzle type valve seat sealing surface and upper cut of valve
body should not exceed 0.03mm).
4.2.2.5 Check height from sealing surface to datum plane of main valve seat, if it is less than
1.5mm, datum plane of main valve seat should be processed.
4.2.3 Valve clack subassemblies check
4.2.3.1 Check sealing surface with naked eyes and check whether guide part has scrap, biting,
agglutination, block trace or not; if there is, outside of guide sleeve and valve clack should be
cleaned.
4.2.3.2 Check interface connecting with valve stem head has crackle or not, it should be changed
if there is.
4.2.3.3 Check abrasion of sealing surface
Standard is as following:
. When sealing surface is abraded to be B C,

process dimension of C to be 0.5mm.
. Minimum permit value of is 0.04mm, when
0.04mm,process dimension of C to be design

dimension.
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. Sealing surface 0.4mm, otherwise it
should be replaced.
4.2.4 Valve stems check
4.2.4.1 Check valve stem surface and whether there is scrape, biting, agglutination and block or
not; it should be cleaned if there is and replaced if serious.
4.2.4.2 Check valve stem bending degree and ellipse degree, bending degree does not exceed
1/1000 and ellipse does not exceed 0.02mm, it should be corrected if it exceeds standard and
replaced if can not be corrected.
Measuring method of valve stem bending degree should be as following, its value do not
exceed 0.05mm:
4.2.4.3 Check valve stem, its abrasion should not exceed 0.1mm, valve stem connection screw
should be complete and cooperate with nuts well. There is no abrasion at top half round. Check
valve stem top with magnetism powder and find whether there is defect such as crack or not, it
should be replaced if there is.
4.2.5 Spring check
4.2.5.1 Remove rust on surface of spring and check the appearance that should be smooth and
free from deleterious crackle, scar or corrosion.
4.2.5.2 Measure free height of the spring that should comply with requirement, the two end faces
should be parallel and vertical to axes; vertical degree should not be bigger than 2mm.
4.2.5.3 Spring can recover to free height after being compressed
4.2.5.4 Spring seat is free from crackle and other defects
4.2.5.5 Contact between spring and spring seat should be stable; it should be corrected if it is not
stable.
4.2.5.6 Spring with corroded surface more than 50% of total area should be replaced.
4.2.6 Check contact of closing ring and lower spring seat, take free journey of closing sleeve and
valve stem as standard, it should be grinded if the contact is not good.
4.2.7 Cooler check
4.2.7.1 Clean cooler inner cavity and remove rust
4.2.7.2 Check appearance and stem guide part with naked eyes
4.2.8 Safety valve sealing surface grinding
4.2.8.1 Preparation of grinding tools
a. Standard first class platform
b. Grinding clamping fixture HB40 cast ironand handle

c. Scraper and file
d. Machinery oil, red lead powder and acetone
e. Absorbent cotton and tar felt
f. #400, #800 and #1200 abrasive paste
4.2.8.2 Grinding tool execution is as following:
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C=d1-(5-6)mm C=d1-(5-6)mm
B=d2+(5-6)mm B=d2+(5-6)mm
G=B+(3-4)mm G=B+(3-4)mm
4.2.8.3 Clean grinding surface and circumference completely, lay on #400 (or same granularity)
abrasive paste on grinding clamping fixture, put it on grinding surface and press it evenly and
completely, screw handle in positive and negative directions slowly through and through until
sealing surface is smooth and free from pit and nick.
4.2.8.4 Grind and polish with #800 and #1200 abrasive paste respectively, old abrasive paste
should be cleaned with acetone once replacing abrasive paste; during polishing grinding, little
abrasive paste should be lay on for grinding until it shows brightness. Finally, lie on little abrasive
paste on tar felt, put a wooden block with outer diameter bigger than sealing surface on sealing
surface, press it then circumvolve for several times until sealing surface shows brightness.
4.2.8.5 Clean the abrasive paste leaking in from back cavity of hot valve clack and on valve body,
check radial goodness of fit of sealing surface with first stage platform and red lead powder,
goodness of fit must exceed 80% of sealing surface width.
4.2.9 Safety valve assembling
4.2.9.1 Clean valve inside, valve clack and valve seat with absorbent cotton immersed in acetone,
install valve clack into valve body. Cotton yarn or flax can not used.
4.2.9.2 Install guide sleeve, position of guide sleeve must be the same with one before dismantling,
proper lubricant should be plastered on inner wall of guide sleeve and outer wall of valve clack
evenly, and trip bolts should be well tightened.
4.2.9.3 After complete overhaul of upper and lower regulation bolts, lubricate oil should be
plastered on previous position for screw threads.
4.2.9.4 Reinstall cooler according to position before dismantling, steam exhaust pipe should be
installed at the position before dismantling.
4.2.9.5 Slip journey control ring onto valve stem, measure valve clack journey to confirm valve
clack position. Its standard value is 12.5+1mm.
4.2.9.6 Confirm that valve stem pin is put into rear spin groove of valve clack; install spring and
upper spring seat, tighten spring compressed bolts to measured height before dismantling, install
chock bolt of spring well.
4.2.9.7 Install spring cover and manual startup device
4.2.9.8 Clean bolt and add sealing gasket, connect the steam exhausting elbow of steam exhaust
flange.
4.3 PCV valve
4.3.1 PCV dismantling
4.3.1.1 Check against operation records, confirm important items and prepare proper tools and
spare parts.
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4.3.1.2 Contact with I & C personnel, confirm that all indications of electric devices are right.
4.3.1.3 Close gate valve manually and then open auxiliary valve manually; it can be dismantled
after confirming that there is no residual steam in valves after discharging steam.
4.3.1.4 Take off link lever and pin at two ends of link lever, take off lever.
4.3.1.5 Dismantle steam exhaust pipe, take off bolts linking electromagnet and supporting frame,
take off electromagnet from frame (connection may not be dismantled if connection of electromagnet is
long; otherwise, contact with I & C personnel to dismantle connections) and put them on designated
rubber, take off bolts linking frame and valve and take off supporting frame from valve.
4.3.1.6 Screw off lock nuts and compression nuts for self-sealing and then take off auxiliary valve
from valve body.
4.3.1.7 Take out guide pipe and valve clack of main valve with special tools and put it then into
special box.
4.3.1.8 Measure the journey of auxiliary valve, which is distance from spring cover to upper end of
auxiliary valve, the standard value is 41.4mm.
4.3.1.9 Take off pin linking spring cover and valve stem, dismantle spring cover and spring and
draw out valve clack from auxiliary valve.
4.3.2 PCV check
4.3.2.1 Clean rust inside valve, check the surface of valve seat whether it has blow spot, trace and
crackle or not, whether there is inner wall thickness decreasing phenomenon due to abrasion and
erosion or not.
4.3.2.2 Check and measure penetration welding metal thickness of sealing surface
4.3.2.3 Check whether there is nick, impress on contacting part of valve inside and sealing ring or
not.
4.3.2.4 Check whether screw threads in valve are complete or not.
4.3.2.5 Check damage on valve clack sealing surface and whether there is scrape, biting,
agglutination and block or not; it should be cleaned if there is and guide sleeve and clack outside
should be napped.
4.3.2.6 Check sealing surface damage condition of auxiliary valve clack and valve seat
4.3.2.7 Check surface rust on valve stem and measure bending degree (not bigger than 1/1000 of
total length) of valve stem.
4.3.2.8 Check abrasion and distortion of sealing ring, replace it if there is abrasion or distortion
4.3.2.9 Spring check
a. Remove rust on surface of spring and check the appearance that should be smooth and
free from deleterious crackle, scar or corrosion.
b. Measure free height of the spring that should comply with requirement, the two end faces
should be parallel and vertical to axes; vertical degree should not be bigger than 2mm.
c. Spring can recover to free height after being compressed
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d. Spring seat is free from crackle and other defects
e. Contact between spring and spring seat should be stable, it should be corrected if it is not
stable.
f. Spring with corroded surface more than 50% of total area should be replaced.
4.3.3 Safety valve sealing surface grinding
4.3.3.1 Preparation of grinding tools
a. Standard first class platform
b. Grinding clamping fixture HB40 cast ironand handle

c. Scraper and file
d. Machinery oil, red lead powder and acetone
e. Absorbent cotton and tar felt
f. #400, #800 and #1200 abrasive paste
4.3.3.2 Grinding tool execution is as following:
4.3.3.3 Clean grinding surface and circumference completely, lay on #400 (or same granularity)
abrasive paste on grinding clamping fixture, put it on grinding surface and press it evenly and
completely, screw handle in positive and negative directions slowly through and through until
sealing surface is smooth and free from pit and nick.
4.3.3.4 Grind and polish with #800 and #1200 abrasive paste respectively, old abrasive paste
should be cleaned with acetone once replacing abrasive paste; during polishing grinding, little
abrasive paste should be lay on for grinding until it shows brightness. Finally, lay on little abrasive
paste on tar felt, put a wooden block with outer diameter bigger than sealing surface on sealing
surface, press it then circumvolve for several times until sealing surface shows brightness.
4.3.3.5 Clean the abrasive paste leaking in from back cavity of hot valve clack and on valve body,
check radial goodness of fit of sealing surface with first stage platform and red lead powder,
goodness of fit must exceed 80% of sealing surface width.
C=d1-(5-6)mm C=d1-(5-6)mm
B=d2+(5-6)mm B=d2+(5-6)mm
G=B+(3-4)mm G=B+(3-4)mm
4.3.4 PCV assembling

4.3.4.1 Clean valve inside, valve clack and valve seat with absorbent cotton immersed in acetone
and replace all the demounted gaskets.
4.3.4.2 Linking auxiliary valve clack and upper valve stem with pin and pull on into valve through
auxiliary valve bottom, install spring seat, spring and spring cover in sequence; the distance
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between spring cover bottom to auxiliary valve upper section should rightly equal to measured
value before dismantling, then fix spring with pin and make spring be with a certain pretension
force.
4.3.4.3 Put guide sleeve of main valve and main valve clack into valve body and make main valve
clack contact with sealing surface of valve seat completely. No dirty or slag inclusion is allowed on
sealing surface.
4.3.4.4 Install auxiliary valve into valve body and pay attention to position of steam exhaust pipe
4.3.4.5 Install sealing ring into valve, screw compression nuts into valve body and lock it tightly
with lock nuts.
4.3.4.6 Put supporting frame on valve body and fix it with faucet.
4.3.4.7 Fix lever on supporting frame with pin and install cotter pin at two ends of pin, regulate
lever to horizontal position with regulation bolts and make regulation bolt lower end be 0.1mm
away from upper valve stem, lock it tightly with lock nut to avoid loosening.
4.3.4.8 Contact with I & C personnel for connection
4.3.4.9 Cold (hot) state commissioning
4.4 Self-sealing Gate Valve Maintenance Process
4.4.1 Preparation
4.4.1.1 Issue work permit ticket, isolate the pipelines at two sides of valve from running
equipments and discharge steam and water completely. If it is electric-driven valve, measures
should be done well to cut power supply.
4.4.1.2 Make sure that there is no pressure in pipeline and valve.
4.4.1.3 Prepare tool and apparatus for maintenance and required parts.
4.4.1.4 Spray loosening agent on valve bolts to be dismantled.
4.4.2. Firstly open valve 2-3 rings manually.
4.4.2.2 Loosen expended ring nut and gland nut of pressing gland packing, demount fixing nails of
valve frame.
4.4.2.3 Demount connection nuts of electric-driven actuator, turn hand wheel in direction of closing
valve element, suspend electric-driven actuator down with chain block, and then demount stuffing
pressing plate, pressing cover and valve frame etc.
4.4.2.4 Move valve tray downwards and then suspend out valve stem, valve tray and gate valve
stop actuator together.
4.4.2.5 Check damage condition at valve port, and mark direction of outlet and inlet of valve
element of gate valve.
4.4.2.6 Demount valve stem from valve tray and dig out gland packing.
4.4.2.7 During dismantling first check actuator, firstly take out pin of connection valve stem and
flashboard frame, take out valve stem from flashboard frame, turn flashboard 90 until it drops
from faucet and take it out from flashboard frame, take out horizontal push ring and the other
flashboard. For this structure, one kind of flashboard frame lower section has through-hole, in
which two pins and one spring is set; under the force of spring, pin gore indentation of flashboard
to avoid flashboard turning. During dismantling, tools may be used to gore pin at one end and then
turn the flashboard.
4.4.2.8 During dismantling the second kind of check actuator, screw off nut firstly, lift up upper
flashboard supporter, hold flashboard to avoid it dropping from flashboard frame, take out
flashboard from its frame.
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4.4.3.1 Special grinding tools can be applied for grinding sealing surface of flashboard valve seat.
4.4.3.2 Valve clack can be grinded manually or by grinding machine, if there are deep blow spots
or grooves, lathe or grinder can be used for process, and polish it after flatting.
4.4.3.3 Clean valve cover and sealing stuffing, remove rust on inner and outer wall of self-sealing
stuffing pressing ring to make pressing ring slip onto upper section of valve cover successfully and
make it convenient to press sealing stuffing tightly.
4.4.3.4 Clean gland packing in stuffing box, check whether stuffing closing ring in it is fine or not,
its clearance between inner aperture and valve stem should comply with requirement; outer ring
and inner wall of stuffing box is free from block.
4.4.3.5 Clean rust on stuffing pressing cover and pressing plate, its surface should be clean and
fine; clearance between pressing cover inner aperture and valve stem should comply with
requirement; outer ring and stuffing box is free from block.
4.4.3.6 Loosen link bolts, check that screw threads part should be fine and nuts should be
complete, screw the nuts to bottom of bolts, pin turns freely.
4.4.3.7 After cleaning rust on valve stem surface, check whether there is bending or not, correct it
to be straight if it necessary. Its trapeziform screw threads should be fine and free from breaking or
damage, spread ceruse after cleaning.
4.4.3.8 Clean six-element ring and its surface should be smooth. Plane should be free from burr or
edge curl.
4.4.3.9 Clean frame and self-sealing bolts and nuts, nuts are complete and turn freely; screw part
should be plastered with ceruse powder.
4.4.3.10 Clean valve stem nuts and inner bearing; clean valve stem nuts, bearing and disc spring
with kerosene. Check whether bearing turns freely or not and disc plate has crack or not.
4.4.3.11 Clean valve stem nuts and check whether inner and outer screw threads are complete or
not. Shell fixing nuts should be firm and reliable. Lining sleeve abrasion should comply with
requirements.
4.4.3.12 Spread butter on bearing and then slips it into valve stem nuts. Disc spring is assembled
as per requirements. Install them into bearing housing in sequence, then lock it tightly with lock
nuts and fix it with bolts finally.
4.4.4. Gate valve assembling
4.4.4.1 Reinstall left and right valve clacks that are grinded to be qualified into flashboard frame,
into which universal jack and horizontal push ring should be put, regulation gasket should be
added according to maintenance condition. Connect assembled check actuator and valve stem.
4.4.4.2 Put valve stem into valve seat together with flashboard for red lead test.
4.4.4.3 Clean valve body inside, valve seat and valve clack. Put valve stem into valve seat
together with flashboard and reinstall valve cover.
4.4.4.4 Add sealing stuffing at valve cover self-sealing part according to requirements, stuffing
specification and rings should comply with standard. Press upper section of stuffing with pressing
ring.
4.4.4.5 Reinstall six-element ring in subsection and in sequence, closing ring should be used to
avoid dropping and cover plate is used for sealing. Screw down self-sealing bolts and nuts.
Note: There is another kind of cover plate that is a structure integrated with frame.
4.4.4.6 Fill valve stem sealing stuffing box fully with stuffing according to requirements, slip into
stuffing pressing cover and pressing plate and tighten it with link bolts, install valve frame and turn
copper nuts clockwise to make frame contact with valve body. Tighten frame and fix nuts.
4.4.4.7 Reinstall valve drive device, screw down jack bolt at connection part and test valve
manually.
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4.4.4.8 Valve scutcheon should be complete and fine; maintenance records are complete,
qualified and accepted.
4.4.4.9 Pipeline heat insulation should be complete and maintenance ground should be clean.
4.4.4.10 Operators should be check equipment environment; original color, insulation and paint
should be fine for the repaired equipments; enclosures, holes, scaffolds comply with safety
requirement; work permit ticket is concluded.
4.4.4.11 Equipment hydraulic test is done with the boiler, check gland packing has no water
leakage; there is no overflow sound or leakage flow on pipeline after valves are closed.
4.5 Outlet valve of boiler water circulating pump
4.5.1 Preparation
4.5.1.1 Confirm that there is no pressure in valve and pipeline connecting to it.
piling up.
4.5.1.3 Prepare all necessary tools and measures.
4.5.2. Valve dismantling
4.5.2.1 Take off valve frame and fixing nuts of valve body, turn the valve stem and make frame
separate from valve stem.
4.5.2.2 Take fixing bolts of lock nuts of upper bearing housing of the frame, screw off nuts and take
out bearing and spring gasket from frame shell.
4.5.2.3 Take off nuts of pressing cover gland packing, take off gland packing and pressing plate.
4.5.2.4 Take off outer closing ring of self-sealing six-element ring.
4.5.2.5 Press down self-sealing valve covers with tool and make clearance between valve cover
and six-element ring, and then take out six-element ring in subsection.
4.5.2.6 Take out valve stem together with valve cover from valve body with lifting tool.
4.5.2.7 Take out valve clack and fixed guide device
4.5.3 Valve check and repair
4.5.3.1 Check and confirm that inner wall of valve body should be smooth, fixed and complete;
valve clack guide frame should be free from block.
4.5.3.2 Check whether valve stem bending degree complies with requirement or not, it should be
corrected or changed if its bending degree exceeds regulated standard.
4.5.3.3 Clean rust on valve stem surface, check whether corrosion on its surface exceeds
regulated standard or not.
4.5.3.4 Check valve stem and trapeziform screw of nuts, which should be free from block; nuts
should be able to be turned freely.
4.5.4 Check sealing surface
4.5.4.1 Check abrasion and erosion of valve seat and sealing surface of valve clack.
4.5.4.2 Clean the surface and check the welding points.
4.5.5 Check bearing
4.5.5.1 Clean bearing and lining sleeve with kerosene, check bearing that should be free from rust,
crackle of abnormal sound when turning.
4.5.5.2 Check connection bolts and nuts.
4.5.6 Valve repair
4.5.6.1 Grinding of valve sealing surface: valve clack can be grinded manually or by grinding
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machine; if there are deep blow spots or grooves, lathe or grinder can be used for process, and
polish it after flatting.
4.5.6.2 Replacing of stuffing for sealing: gland packing stuffing at valve cover sealing part should
be cleaned, remove rust on self-sealing stuffing pressing ring and polish it to be clean, slip on
pressing ring into valve cover, clearance of allocating convex should comply with requirement.
4.5.6.3 Sealing stuffing box of valve stem should be cleaned and its inner wall should be polished,
remove rust on stuffing pressing flange and pressing plate, clearances between pressing flange
inner aperture and valve steam, outer aperture and stuffing box should comply with requirement.
4.5.6.4 Loosen link bolts of pressing flange, check that screw part and nuts should be fine, nuts
can be screwed on to bolts bottom and pin can turn freely.
4.5.6.5 Fill sealing stuffing into stuffing box in sequence, screw on bolts after pressing ring by ring
tightly.
4.6 Regulation valve maintenance quality standard
4.6.1 Preparation
4.6.1.1 Confirm that there is no work in valve inner cavity and pipes connecting to it, medium are
free from pressure.
piling up.
4.6.1.3 Prepare all necessary apparatus for mapping.
4.6.2 Squirrel-cage regulation valve dismantling and check
4.6.2.1 Open valve 2-3 rings manually. Screw off electric actuator and dismantle the actuator.
4.6.2.2 Loosen nuts of upper cover on valve and take off upper cover. Take out upper cover and
sealing serrated gasket of valve body.
4.6.2.3 Screw off valve seat sleeve for check.
4.6.2.4 Loosen tightening nuts of gland packing pressing cover, take off finger and fixing pin of
valve stem, screw off and take out copper nut from valve stem with spanner.
4.6.2.5 Take off valve stem copper nut and outer ring of half-round closing ring connecting to frame,
take off half-round closing ring, take out copper nut, bearing and gasket from frame.
4.6.2.6 Loosen valve stem and fixing jack bolts of valve element sleeve, screw off sleeve of valve
element.
4.6.3 Squirrel-cage regulation valve overhaul
4.6.3.1 Check valve seat and sleeve in valve body are free from swinging and well fixed on valve
body.
4.6.3.2 There is no defect such as sand hole and crackle inside valve body, its outlet and inlet are
smooth.
4.6.3.3 Clean gland packing in gland packing box, and polish seat ring of gland packing to be
clean.
4.6.3.4 Check that cooperation of plane bearing, ball bearing and frame are fine and free from
dropping; otherwise, it should be changed.
4.6.3.5 Valve stem copper nuts trapeziform screw is fine and free from breaking and biting.
4.6.3.6 Valve stem trapeziform screw is fine and its bending degree and ellipse degree comply
with requirements. Its surface is clean and free from corrosion.
4.6.3.7 The cooperation between valve clack sleeve and sleeve sealing surface of valve seat is
good, there is no groove, and sleeve apertures are fine and complete. Sleeve is agile and free
from block.
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4.6.3.8 Check all the tightening bolts and nuts. Screw threads are free from breaking and biting.
Nuts are able to be screwed on to bottom of bolts. Graphite powder should be plastered during
assembling.
4.6.3.9 Sealing surface at connection of valve body and valve cover should be smooth; there is no
serrated gasket trace.
4.6.4. Squirrel-cage regulation valve assembling
4.6.4.1 Screw on valve seat sleeve to inner sleeve of valve body and tighten it well.
4.6.4.2 Screw on valve stem and valve clack sleeve tightly and fix it with fixing bolts.
4.6.4.3 Assemble copper nuts, bearing and gaskets in sequence, put it into shell at upper section
of frame, fix it with fixing half round ring and slip on closing ring well outside half-round ring.
4.6.4.4 Insert valve stem into valve cover and screw it onto copper nut of valve stem. Install
stuffing seat ring, stuffing pressing cover and scale fingers well at the same time.
4.6.4.5 Put serrated gasket between valve cover and sealing surface of valve body, assemble
valve cover, tightening bolts and nuts, screw them symmetrically with even force and proper
clearance.
4.6.4.6 Fill gland packing box fully with stuffing according to requirements, press upper section
well with stuffing pressing cover and screw tightening bolts tightly.
4.6.4.7 Install keys onto copper nuts, install motor-drive device well and screw on tightening bolts
tightly. Open and close valves manually, turn the valve to full open state after confirming there is
no problem.
4.6.5 Baffle regulation valve dismantling
4.6.5.1 Screw off retainer bolts of electric actuator and take off electric actuator.
4.6.5.2 Take off fixing bolts of valve frame and valve body, turn valve stem copper nuts in
anticlockwise after taking off self-sealing to separate frame from valve stem. For valves with
double stems, fingers should be taken off firstly, turn upper stem with spanner to separate upper
and lower stems, and then take off the frame.
4.6.5.3 Take off fixing bolts of lock nuts in bearing housing at upper section of frame, screw off lock
nuts, and take bearing and spring gaskets out form frame shell.
4.6.5.4 Take off gland packing pressing cover nuts and take off gland packing pressing cover and
pressing plates.
4.6.5.5 Take off outer closing ring of six-element ring.
4.6.5.6 Press down self-sealing valve covers with tool and make clearance between valve cover
and six-element ring, and then take out six-element ring in subsection.
4.6.5.7 Take out valve stem together with valve cover from valve body with lifting tool.
4.6.5.8 Check abrasion of valve seat and seal valve body with covering plate.
4.6.5.9 Take out valve stem from stem and keep the dismantled parts well.
4.6.6 Baffle regulation valve overhaul
4.6.6.1 Check abrasion and erosion of outlet aperture of valve seat and take records well. Clean
the surface and smooth holes and apertures, check welding points, burr on orifice plate can be
polished with whetstone.
4.6.6.2 Check sealing surface of valve clack damper, common defects can be grinded with
whetstone. After repairing welding for deep groove, it should be processed to recover to original
dimension. For regulation valves with throttled holes on damper should be check whether throttled
hole are eroded and throughflow holes are distorted or not.
4.6.6.3 Groove at side of damper and track inside valve body should be smooth, fixed and
complete and free from block; otherwise it should be repaired.
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4.6.6.4 Check whether grooves at connection of damper and valve stem has crake, damage or not;
destructive inspection should be done if it is necessary.
4.6.6.5 Replacing stuffing sealing
A Gland packing stuffing at valve cover sealing part should be cleaned, remove rust on
self-sealing stuffing pressing ring and polish it to be clean, slip on pressing ring into valve cover,
clearance of allocating convex should comply with requirement.
B Sealing stuffing box of valve stem should be cleaned and its inner wall should be polished,
remove rust on stuffing pressing flange and pressing plate, clearances between pressing flange
inner aperture and valve stem, outer aperture and stuffing box should comply with requirement.
Otherwise, it should be repaired.
C Loosen link bolts of pressing flange, check that screw part and nuts should be fine, nuts can
be screwed on to bolts bottom and pin can turn freely.
4.6.6.6 Valve stem
A Check whether valve stem bending degree complies with requirement or not, it should be
corrected or changed if bending degree exceeds regulated standard.
B Clean rust on valve stems surface, check whether corrosion on its surface exceeds
regulated standard or not.
C Assemble valve stem and flashboard, it should be agile and free from block. End section
round convexity should contact with it when it acts downwards; shoulder section does not bear
force.
4.6.6.7 Valve stems nuts
A Check nuts inner lining sleeve screw of stem, which should be free from breaking or biting;
otherwise it should be changed.
B Clean bearing and lining sleeve with kerosene, check bearing that should be free from rust,
crackle or abnormal sound when turning.
C Check and clean disc spring, change it if there is any crackle or obvious distortion.
D Check valve stem copper nut and fixing bolts of outer sleeve, there should be no looseness
after it is sealed.
4.6.6.8 For the valves with double stems, connection screw at stem end of lower valve should be
complete and fine; it should be repaired or changed if there is defect.
4.6.7 Baffle type regulation valve assembling
4.6.7.1 Hang baffle well with valve stem and put it into valve body along track, measure the
clearances between baffle and valve seat, valve body track and baffle.
4.6.7.2 Slip self-sealing valve cover into valve stem and put it into valve body; fill self-sealing gland
packing as per requirements and press with stuffing pressing ring finally.
4.6.7.3 Reinstall six-element ring in sequence and screw valve cover lifting bolts to valve cover.
4.6.7.4 Stuff gland packing box of valve stem with stuffing as per requirements, press the upper
section with stuffing pressing cover and screw down bolts.
4.6.7.5 Reinstall valve stem nuts and inner parts into bearing housing, grease should be plastered
on bearing and disc spring should be reinstalled as per requirements, lock it tightly with lock nuts
and avoid dropping with fixing nails.
4.6.7.6 Suspend frame onto valve stem with lifting tools and spin stem nuts to make frame drop on
valve body and then tighten it with bolts and nuts. During installing frame, screw on valve stem and
stem nuts synchronously to connect upper and lower screw threads of valve stem, and then fix
upper and lower stem firmly with spanner.
4.6.7.7 Reinstall valve stem journey indication clamp plate, screw down bolts, indication plate
should joint to the side with processed plane of valve frame.
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4.6.7.8 Reinstall electric-driven device of valve and fix the bolts.
4.6.7.9 Open and close valves manually, test whether it is agile or not.
4.6.8 Rotary regulation valve dismantling
4.6.8.1 Dismantle valve turning handle from drive stem, preserve connection pin well.
4.6.8.2 Screw off closing lever at front end of valve stem, dismantle closing lever, loosen handle
tightening nut and take off handle. Loosen gland packing pressing cover nut and take off pressing
cover.
4.6.8.3 Dismantle fixing bolts at closing lever at front end of valve stem and preserve it well.
4.6.8.4 Loosen tightening nuts of valve cover and hang lifting tools on valve cover, suspend valve
cover firmly, loosen all nuts and suspend valve cover away from valve body.
4.6.8.5 Draw out valve element from valve body, mark opening and closing on shaft end face of
valve element for reinstalling.
4.6.9 Rotary regulation valve repair
4.6.9.1 Check whether sealing surfaces of valve seat and valve element has groove and nick or
not.
4.6.9.2 Clean burr and trace on valve clack surface with sand paper, test and check cooperation
clearance; it should be cleaned or changed if there is biggish defect.
4.6.9.3 Check valve cover and clean gasket, clean the joint surface clean, and treat it if defect is
found.
4.6.9.4 Clean all tightening bolts and repair screw threads part to make cooperation between bolts
and nuts agile and spread ceruse oil for preservation.
4.6.9.5 Clean the stuffing box of valve cover, fish out old stuffing material and clean inner wall of
box with sand cloth.
4.6.9.6 Clean valve cover stuffing box and fish out oil stuffing, grind stuffing pressing cover surface
for cleaning rust.
4.6.9.7 Check and make sure that connection between valve element and valve stem is firm.
4.6.9.8 All drive connection lever should be complete and drive is reliable. All connection pins
should be agile and free from block; its surface should be grinded and plastered with a little grease
for lubrication.
4.6.10 Rotary regulation valve assembling
4.6.10.1 Check valve body that should be free from impurities and clean the inside of the valve.
4.6.10.2 Reinstall the valve body after cleaning valve clack, test its turning. Take opening and
closing marks after aligning valve clack window and valve seat window.
4.6.10.3 Spread ceruse oil on all bolts of valve covers, put asbestos gasket plastered with graphite
powder into valve cover joint surface, suspend valve cover and screw on fixing nuts. Symmetric
method should be adopted to ensure even clearances around valve cover.
4.6.10.4 Reinstall stuffing closing ring and stuff stuffing as per requirements. Press stuffing
pressing cover tightly.
4.6.10.5 Reinstall spin handle and connection lever parts at shaft end, regulate its openness well.
4.6.10.6 Reinstall horizontal lever at front end of valve lever, tighten bolts and nuts well.
4.6.10.7 Clean up maintenance records and all dimensions, clean site and hang on plates for
equipments.
4.6.11 After valve overhaul is completed, clean up the site and hang up scutcheon for the
equipments.
4.6.11.1 Operators should check equipment environment and accept it after it is qualified.
45
Conclude the work permit ticket.
4.6.11.2 Tightness test of valve can be done together with hydraulic test, check whether openness
of valve is normal or not, whether gland packing leaks water or not. If there is no problem,
tightness test of valve is qualified.
4.7 Check valve maintenance process and quality standard
4.7.1 Preparation
4.7.1.1 Confirm that there is no work in valve inner cavity and pipes connecting to it, medium are
free from pressure.
piling up.
4.7.1.3 Prepare all necessary apparatus for mapping.
4.7.2.1 Loosen cover plate nuts and take off cover plate.
4.7.2.2 Take out closing rings of six-element ring.
4.7.2.3 Suspend valve cover out from valve body with special tools and take off stuffing pressing
ring.
4.7.2.4 Take out six-element ring in subsections.
4.7.2.5 Suspend valve cover out of valve body and take off stuffing pressing ring.
4.7.2.6 Lift valve clack can be taken out directly, check joint surface of valve element and valve
seat and decide repair method.
4.7.2.7 For swing check valve, fixing pin of connection frame can be taken down, then take off
valve clack from connection frame, check the interface of valve clack.
4.7.2.8 Cover valve and seal.
4.7.3.1 Check that valve body should be free from sand hole, crackle and corrosion, repairing
welding should be done if said defects are found.
4.7.3.2 Sealing surface of valve seat should be grinded manually or mechanically to clean groove
and pit on the surface to make sealing surface meet quality requirements.
4.7.3.3 Defects on sealing surface of valve clack can be grinded with flat plate or sand paper, if the
defect is serious, valve clack can be sent to lathe and then for grinding.
4.7.3.4 Clean valve cover and remove sealing stuffing on it, grind stuffing pressing ring and grind it
clean, check clearances between sealing matters, lift nuts screw part should be complete and nuts
should be agile.
4.7.3.5 Repair six-element ring, surface is smooth and clearances between clip grooves should
comply with requirements; otherwise it should be processed.
4.7.3.6 For lift valve clack, valve clack and positioning sleeve should be grinded completely to be
clean, remove rust and then test whether it is agile or not.
4.7.3.7 For swing check valve, its fixing pin should be smooth and straight and connection with
fixing end should be reliable. Pin should be free from block during free lift and drop in vertical
direction.
4.7.4 Check valve assembling
4.7.4.1 Put valve clack into valve; for swing check valve, connect valve clack and connection
frame with pin and then connect connection frame and fixing end in valve body with shaft.
4.7.4.2 Put valve cover into valve body, stuff and press sealing as per requirement.
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4.7.4.3 Slip stuffing pressing ring on valve cover sealing part and press stuffing well.
4.7.4.4 Reinstall six-element ring in sections with clearances between sections are even, then
install closing ring to avoid dropping.
4.7.4.5 Reinstall cover plate and press it on six-element ring, screw down nuts on cover plate to
press self-sealing stuffing tightly.
4.7.4.6 Clean the ground at valve and around.
4.7.4.7 Operators should check equipment environment and accept it after it is qualified. Conclude
the work permit ticket.
4.7.5 Do the hydraulic test together with boiler; it is qualified after checking and confirming that
there is no water leakage at gland packing.
4.8 Vessel maintenance process
4.8.1 Preparation
4.8.1.1 Prepare special tools for overhaul, general tools, spare parts and materials.
4.8.1.2 Prepare lighting and lifting tools.
4.8.1.3 Scaffold should be built at high altitude and inconvenient places for overhaul and frame
plate should be laid, measures for avoiding dropping should be well made.
4.8.1.4 Saturate a little kerosene on bolts to be dismantled for convenience of dismantling.
4.8.1.5 Contact with operators, confirm that pressure in vessel has decreased to zero and water is
completely discharged, all the other systems are disconnected. Then dismantling can be done.
4.8.1.6 After dismantling vessel, supervision personnel outside vessel should always keep in
contact with working personnel inside vessel to avoid accident.
4.8.1.7 Sufficient ventilation should be done before entering into vessel; oxygen is not allowed to
be charged into vessel.
4.8.1.8 For the working personnel entering into vessel, pockets of whom should be free from
sporadic things to avoid dropping into pipes or leaving in vessel due to mistake.
4.8.2 Vessel overhaul
4.8.2.1 Dismantle bolts and nuts of manholes of vessel. Bolts cooperation should be agile and
graphite powder should be plastered during assembling.
4.8.2.2 Demount bolts of safety valve, dismantle and check safety valve and clean flange joint
face.
4.8.2.3 Dismantle water level indicator, repair steam-water valve and change mica.
4.8.2.4 Demount pressure meter for calibration, check and repair pressure meter.
4.8.2.5 Repair steam exhaust valve and water discharging valve of vessel.
4.8.2.6 Remove rust on inner wall of vessel, check welding lines that should be free from crackle
and corrosion, repairing welding should be done for special conditions.
4.8.2.7 Vessel assembling can be done as references of sections of safety valve and check valve.
4.8.2.8 Check that all pipelines should be smooth, abrasion corrosion should not exceed 1/3 of
original thickness; otherwise it should be changed.
4.8.2.9 Test all part in hot state, there should be free from leakage.
4.8.2.10 clean site, all heat insulations should be complete and qualified and accepted.
4.8.3 Inspection report
4.8.3.1 Inspectors should fill Pressure Vessel Inspection Report carefully after inspection.
4.8.3.2 For the vessels with serious crackles by inspection, analyze its reason and take measures
47
to clean and repair, replace or discard as useless.
4.9 Steam water pipeline maintenance standard
4.9.1 Quality check before using pipeline
4.9.1.1 Check inner and outer wall of pipe, its surface should be glabrous and free from crackle,
double skin, and abrasion and hollow. Thickness of rust-removed pipe wall should be no less than
minimum permit value of wall thickness. Permit depth: for cold drawn tube, its depth should be no
more than 4% of wall thickness and maximum depth is no more than 0.3mm; for hot cold tube, its
thickness should be no more than 5% of wall thickness and its depth should be no more than 0.5mm.
4.9.1.2 Measure pipe diameter and pipe wall thickness with caliper and micrometer. During check,
take 3-4 points along pipe length for measuring outer diameter and take 3-4 points at pipe ends for
measuring pipe wall thickness. Dimension error should comply with standard according to different
usage. Error of outer diameter and standard dimension should be no more than 0.5-1mm; pipe
wall thickness error is 10-15% of wall thickness.
4.9.1.3 Check ellipse and pipe diameter. Select 3-4 points from total pipe length with micrometer
and self-made sampling plate for measuring. Absolute ellipse degree is difference of maximum
and minimum diameter of measured section, it is generally required that relative ellipse degree
should not exceed 0.05.
4.9.1.4 Wholly check pipes with welding lines, inner diameter of ball is 80%-85% of nominal
diameter.
4.9.1.5 Check specifications of all pipes before using according to design requirements and find
out steel number. Check its chemical content, mechanical performance and application range
according to leaving factory certificate. Spectral analysis should be done to alloy steel, check that
whether chemical content comply with steel number or not. For strictly required parts, flattening
test and hydraulic test should be done for pipe materials.
4.9.2 Pipeline welding
4.9.2.1 Distance between pipe connection and bending starting point of siphon should not smaller
then pipe outer diameter and be no less than 100mm.
4.9.2.2 Pipe connection should not be arranged on supporting and suspending frame, it should be
at least 50mm away from suspending and supporting frame.
4.9.2.3 Distance between two connections of pipe should be no less than pipe outer diameter and
150mm; welding crater requiring hot treatment after welding should be at least 5 times of welding
line width away from suspending and supporting edge and no less than 100mm.
4.9.2.4 Pipe connection should avoid opening positions of drainage water and instrumental meter
pipes; it should be at least 50mm away from edge of openings and no less than aperture.
4.9.2.5 No connection is allowed fro the pipe section in wall and floor plate when pipe penetrate
through isolation wall and floor plate.
4.9.2.6 High pressure pipe welding line is not allowed to be arranged at elbow part of pipes.
4.9.2.7 Butt seam welding centerline should be at least 70mm away from pipe bending starting
point or outer wall of drum header and edge of suspending and supporting frame.
4.9.2.8 Distance of butt seam welding centerline on pipeline should be no less than pipe outer
diameter and no less than 100mm; distance from it to edge of suspending and supporting frame
should be 70mm at least.
4.9.2.9 Distance between two butt wildling seam centerline should be no less than 150mm and no
less than pipe diameter.
4.9.2.10 Spectroscopic analysis or titration test should be done for alloy steel pipes before
assembling to differentiate steel number.
4.9.2.11 Except for cold draught welding carter in design specification, alignment is not allowed
during assembling welding parts to avoid additional stress.
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4.9.2.12 Pipe connection process must comply with design drawings or technical requirements,
pipe port plane should be vertical to pipe center and its error value should not exceed 1mm.
4.9.2.13 Mechanical method should be adopted for processing pipe end and included angle; if air
cutting is used, mechanical process must be done again.
4.9.2.14 Oil, paint, dirty and rust within 20mm of outer wall and in included surface of pipe
connection should be plastered until it shows metal gloss.
4.9.2.15 Error value of connection centerline should not exceed 1/200mm.
4.9.2.16 after pipe alignment, spot welding should be done for fixing. Do 2-4 spot welding with
length of about 10-20mm
4.9.2.17 Support frame should be set at 1 meter of two sides of connection, two ends of pipe
should be blocked to avoid draught.
4.9.3. Notes for pipeline replacement
4.9.3.1 Pipelines installed in drainage water and water discharging system should be with a certain
incline, which is 3-5/1000 generally.
4.9.3.2 There should be expansion clearance when pipeline is penetrating wall and floor plate.
4.9.3.3 Clean inner part of pipe section to be changed. Seal the open pipe port in time when work
stops intermediately.
4.9.3.4 Pipe insulation is complete and with obvious color and signs.
4.9.3.5 Pipe expansion indicator should be complete and zero position is right.
4.9.3.6 Record maintenance technical date such as name, position, specification, length and
damage condition before replacing into maintenance record book, draw sketch map if it is
necessary for the convenience of check during maintenance in future.
4.9.4. Pipe and accessories metal supervision
4.9.4.1 According to the requirements of metal supervision department, maintenance personnel
should cooperate and assist for check and offer convenience.
A Creep measuring
B Metallographic inspection
C Fault detection
D Cutting sample for intension test
4.9.4.2 Maintenance shift should come down on test report from metal supervision department and
take records.
4.9.4.3 Find out the parts requiring check according to major and minor overhaul and defects
checking records.
4.9.4.4 Find out corrosion of welding points and pipeline according to conditions of dismantling of
equipments, treat it and record it well.
4.9.4.5 Complete check of suspending and supporting frame.
4.9.4.6 Check indication and action condition of pipeline expansion and take records well for
convenience of analysis.
4.9.5. Connection type dimension of pipe and pipe accessories:
4.9.5.1 Connection type dimension of pipe and pipe accessories with same wall thickness
Included Welding Pipe wall Connection structure dimension
49
angle type thickness (degree) ( degree) A mm B mm R mm C mm
type S
(mm)
V type Gas 6 30-45
welding
16 30-35
Arc
welding 6 30-45
Argon arc
welding
rendering
Double Arc >20 30-35 10-15 3-5 1-2 5
V type welding
>20 30-45 8-12 3-5 1-2 5
Argon arc
welding
rendering
U type Arc 20-60 10-15 2-3 1-2 3-5
welding
20-60 10-15 2-3 1-2 3-5
Argon arc
welding
rendering
4.9.5.2 Type of welding pieces with different thickness
A Inner wall dimensions are not equal and outer wall is complete.
B Outer wall dimensions are not equal and inner wall is complete.
C Both inner & outer wall dimensions are not equal.
D Inner wall dimensions are different and differential thickness 5mm.
4.10 Suspending and supporting frame overhaul
4.10.1 Function of suspending and supporting frame
On the one hand, it bears weight of itself and flowing medium; on the other hand, it is for fixing
pipes, bearing all forces and moment of pipes, distributing these forces reasonably, guiding
pipeline displacement reasonably, meeting the requirements of heat compensation and
displacement, ensuring pipeline stability, reducing pipeline vibration, all of which are to ensure
safety operation of the pipelines.
4.10.2 Type of suspending and supporting frame
4.10.2.1 Fixed supporting frame: it is to fix pipes and will displace or turn when heat expansion
happens; it bears weight, thrust and torque of pipeline.
4.10.2.2 Moving supporting frame: Except for bearing pipeline weight, it limits pipeline
displacement and direction to make supporting point move in regulated direction. Set moving
supporting frame at places on pipeline with no vertical displacement or little vertical displacement.
Moving supporting frame can be divided into sliding supporting frame and rolling supporting frame.
4.10.2.3 Guide supporting frame: it bears pipeline weight, limits or guides pipeline displacement or
direction. Guide supporting frame is only allowed to set on horizontal pipelines with axial horizontal
displacement part of pipeline. Guide supporting frame on vertical pipeline does not bear pipeline
weight but limits displacement direction and prevents pipeline vibration.
4.10.2.4 Suspending frame: Suspending frame can be divided into common suspending frame
and spring suspending frame. Common suspending frame can ensure horizontal free
displacement of pipeline. Spring suspending frame is used at places with both vertical and axial
displacement.
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4.10.3. Check content of suspending and supporting frame
4.10.3.1 Root part of supporting and suspending frame is set firmly and free from deflection or
collapse. Truss has high rigid and free from distortion; when it is fixed frame, pipeline is laid on
supporting pillow, clip hoop should cling to pipe supporting frame and free from displacement.
4.10.3.2 For suspending and supporting frames with constant function, specification and
installation should comply with design requirements, welding for installation should be firm; for
sliding supporting frame, its sliding surface should be clean and hot displacement should comply
with requirement.
4.10.3.3 For spring suspending frame, suspending lever should be free from bending and
compression of spring should comply with requirement.
4.10.3.4 For guide supporting frame, pipe and supporting pillow cling tightly, guide slot should be
welded firmly and support pillow lies in guide slot with even clearances and good sliding.
4.10.3.5 For all fixing frame, guide suspending, supporting and moving frames, there should be no
impurities in components. Rolling frame, contact of supporting seat, soleplate and ball bearing
should be fine.
. Maintenance Quality Standard

5.1 VELAN check valve overhaul quality standard
5.1.1 Valve body should be free from crackle, sand hole and erosion. Inlet and outlet pipeline of
valve body should be smooth and free from impurities. Connecting screw threads of valve body
and valve cover should keep fine and can be screwed off to screw threads bottom freely.
5.1.2 Valve stem bending degree should not exceed 0.1-0.25mm, ellipse degree should not
exceed 0.02-0.05mm; its rust and abrasion should not exceed 0.1-0.2mm, screw threads of valve
stem should be good and cooperation with screw thread sleeve should be agile. It should be
replaced if it does not comply with above requirements.
5.1.3 Valve clack and valve seat sealing surface should be free from seeable spot and groove. Its
full ring is bright, surface roughness is under 0.01mm and interface should be above 2/3 of port
width of the whole ring.
5.1.4 All bolts, nuts and screw threads should be complete and cooperation should be proper.
5.1.5 Clearance between valve stem and stuffing seat clearance is 0.1-0.2mm, clearance of
stuffing pressing cover outer wall and stuffing box is 0.2-0.3mm and do not exceed 0.5mm at most.
5.1.6 Trapeziform of valve stem nuts should be fine and abrasion should not be bigger than 1/3 of
original teeth thickness, fixing bolts of outer shell should be fixed, valves with no fixing bolts should
be fixed by spot welding and free from loosening.
5.1.7 Little grease should be plastered in track groove before installing ball bearing. Ball bearing
should be 12, check its running after ball bearing is installed.
5.1.8 Specification and model of using stuffing should comply with medium pressure and
temperature requirements of pipeline and valves.
5.1.9 Stuffing connection angle is 30 or 45, every two neighboring ring stuffing connection should
stagger 90-180, length put into stuffing box should be proper and free from clearance or folding.
5.1.10 After screwing down link bolts, pressing plate should be smooth and clearances among
valve stem, pressing cover and stuffing box should be even, height of stuffing cover pressed into
stuffing box is 1/3 of itself and not less than 3mm. Link bolts and nuts cooperation is agile and free
from block; screw thread part is free from sliding and breaking, nuts can be screwed down to
bottom of bolts.
5.1.11 Spin valve stem manually after filling gland packing, valve stem can be operated freely with
normal force and free from block.
5.2 Self-sealing flashboard valve overhaul quality standard
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5.2.1 After overhaul, sealing surfaces of valve clack and valve seat should be free from spot and
groove, their contacting part should be above 2/3 of valve clack port width, roughness of surface
should be under 0.4.
5.2.2 Clearance between valve stem and stuffing closing ring is 0.1-0.3mm and should not exceed
0.5mm at most; clearances of stuffing pressing cover, stuffing box and valve stem clearance
should be proper and is 0.1-0.2mm generally.
5.2.3 Valve stem bending degree should not exceed 0.1-0.25mm and rust depth on surface should
not exceed 0.1-0.2mm. Screw threads of valve stem are complete and cooperation with nuts is
agile.
5.2.4 Height of six-element ring in valve groove should be consistent.
5.2.5 Disc spring should be free from crackle and distortion; otherwise it should be replaced.
5.2.6 Trapeziform of valve stem nuts should be fine and abrasion should not be bigger than 1/3 of
original teeth thickness, inner lining sleeve screw threads should be complete and free from
wrongness and breaking.
5.2.7 All bearing parts should be complete and turn freely, inner & outer sleeve and steel ball
surface should be free from crackle, rust and double skin.
5.2.8 Fixing nails on surface of lock nuts surface should not be loosened. Valve stem nuts turn
freely and axial clearance should not be bigger than 0.35mm.
5.2.9 During assembling test, residual surface K value should be ensured after valve clack
inserting into valve seat. Dropping-proof device should be complete after assembling left and right
gate plate.
5.2.10 Lay on graphite powder on cooperation part of valve body and cover and gland packing.
5.2.11 Temperature and pressure of using stuffing should comply with requirements.
5.2.12 Specification of stuffing should comply with stuffing box dimension, stuffing filling height
should comply with valve dimension and leave a hot tightening surplus. Height of stuffing cover
pressed into stuffing box is 1/3 of itself.
5.3 Boiler water circulating pump outlet valve overhaul quality standard
5.3.1 Valve body should be free from crackle, sand hole and serious erosion. Outlet & inlet pipeline
of valve body should be smooth and free from impurities. Connection screws of valve body and
valve cover should be complete and can be screwed down to bottom easily.
5.3.2 Valve bending degree should not exceed 0.1-0.25mm, ellipse degree should not exceed
0.02-0.05mm; its rust and abrasion should not exceed 0.1-0.2mm, screw threads of valve stem
should be good and cooperation with screw thread sleeve should be agile. It should be replaced if
it does not comply with above requirements.
5.3.3 Surface roughness Valve clack and valve seat sealing surface should be free from seeable
spot and groove. Its full ring is bright, surface roughness should be under V and interface should
be above 2/3 of port width of the whole ring. Taper sealing surface of valve clack should be in
consistent with valve seat, it is best that interface of valve clack is in middle of conical surface.
5.3.4 Bearing should be free from rust and crackle; there is no abnormal sound during running.
5.3.5 Bolts, nuts and screw threads should be complete and cooperation should be proper.
5.3.6 Stuffing connection angle is 30 or 45, every two neighboring ring stuffing connection should
stagger 90-180, length put into stuffing box should be proper and free from clearance or folding.
5.3.7 After screwing down link bolts, pressing plate should be smooth and clearances among valve
stem, pressing cover and stuffing box should be even, height of stuffing cover pressed into stuffing
box is 1/3 of itself and not less than 3mm. Link bolts and nuts cooperation is agile and free from
block; screw thread part is free from sliding and breaking, nuts can be screwed down to bottom of
bolts. Clearances of stuffing seat rings should be 0.1-0.2mm and clearance between stuffing
pressing cover outer wall and stuffing box is 0.2-0.3mm and does not exceed 0.5mm at most.
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5.3.8 Spin valve stem manually after filling gland packing, valve stem can be operated freely with
normal force and free from block.
5.4 Regulation valve overhaul quality standard
5.4.1 Valve stem copper nut trapeziform screw abrasion should not be bigger than 1/3 of original
teeth thickness.
5.4.2 Valve stem bending degree should not exceed 0.1-0.25mm and stems average corrosion
depth on surface deeper than 0.25mm should be replaced.
5.4.3 Valves with biggish groove on sealing surface and erosion distortion of sleeve holes and
apertures should be replaced. Sealing surface roughness should be under.
5.4.4 Stuffing pressing cover and seat ring should be complete and free from rust, inner wall of
stuffing box is clean; clearances of valve stem and pressing cover and between rings should be
0.1-0.3mm, clearances between stuffing pressing cover, stuffing box and valve stem should be
proper of 0.2-0.3mm generally.
5.4.5 A little grease should be plastered on bearing during assembling.
5.4.6 After tightening bolts, spin copper nuts to raise it or close valve stem, check cooperation of
piston sleeve.
5.4.7 After screwing down pressing cover bolts, keep pressing cover smooth and tightening stress
even. Clearances all around pressing cover and valve stem are consistent, height of stuffing cover
pressed into stuffing box should be 1/3 of it.
5.4.8 Connection between valve element and stem is hanging type; take off valve element
immediately after suspending out valve body to avoid damage due to dropping.
5.4.9 Outlet & inlet holes of orifice plate should be smooth and complete. Leakage due to part
erosion should not exceed 2% of flow, it should be replaced if it exceeds standard.
5.4.10 Baffle surface of valve clack should be glabrous and free from burr and nick; its surface
roughness should be under, after putting baffle into valve body and jointing outlet side strictly,
clearance between the other side and inlet valve seat should be 1-5mm.
5.4.11 If crackles occur on orifices or through-flow holes on baffle, baffle should be changed.
5.4.12 Baffle should move freely in track of valve body and free from block. After sealing surface
jointing valve seat tightly, clearance of no less than 0.5mm should be preserved between side
groove of baffle and slideway.
5.4.13 Temperature and pressure of using stuffing should comply with requirements of valve
medium, stuffing length should be proper; connection of stuffing box should be free from clearance
or folding.
5.4.14 Stuffing pressing cover and seat ring should be complete and free from rust, inner wall of
stuffing box is clean; clearances of valve stem and pressing cover and between rings should be
0.1-0.3mm, clearances between stuffing pressing cover, stuffing box and valve stem should be
proper of 0.2-0.3mm generally.
5.4.15 Valve stem bending degree should not exceed 0.1-0.25mm and ellipse degree should not
exceed 0.02-0.05mm.
5.4.16 Valve stem surface should be glabrous, there should be free from exfoliation corrosion and
dilapidation phenomenon; valve stems with average corrosion depth of deeper than 0.25mm
should be replaced.
5.4.17 Bearing should be complete and turn freely; surfaces of pressing cover and steel ball
should be free from rust and crackles.
5.4.18 Disc spring should be free from crackle and obvious distortion, assembling should comply
with requirements. Change it if there is defect.
5.4.19 Valve stem copper nut turn freely and axial clearance should be ensured to be no bigger
53
than 0.35mm. Copper nut trapeziform screw threads should be complete and its abrasion should
be not bigger than 1/3 of original teeth thickness.
5.4.20 Valve stem screw threads should be free from breaking and biting and its connection with
upper valve stem is fixed.
5.4.21 After screwing down link bolts, pressing plate should be smooth and tightening stress is
even, clearances of stuffing pressing cover, pressing plate inner hole and valve stem should be in
consistent. Height of stuffing cover pressed into stuffing box is 1/3 of itself.
5.4.22 Interface of valve seat and valve element should be smooth and free from burr and nick, its
ellipse does not exceed 0.03mm and valve stem bending degree does not exceed 0.1-0.25mm
and ellipse does not exceed 0.02-0.05mm.
5.4.23 Clearance between stuffing seat ring and valve stem should not exceed 0.2mm,
cooperation clearance between valve stem and valve cover should not exceed 0.18mm.
5.4.24 Temperature and pressure of using stuffing should comply with requirements. Connections
of all rings should be put into stuffing box with stagger angle of 90-120 and free from clearance
or folding. Height of stuffing cover pressed into stuffing box is 1/3 of itself.
5.4.25 Reinstall valve stem as per signs and make windows align and comply with requirements.
There is no impurities blocking drive part and drive devices are agile and reliable.
5.5 Non-return valve overhaul quality standard
5.5.1 Valve body inside is clean and free from rust, erosion or corrosion. Inlet and outlet should be
smooth with no impurities.
5.5.2 Valve clack and sealing surface of valve seat should be free from pit, groove or corrosion.
Full ring of sealing surface is bright and surface degree of polish is under, contact width should
be above 2/3 of full valve port.
5.5.3 Bolts screw threads should be complete and free from breaking or biting. Nuts should be
agile; screw down bolts screw threads of bottom manually and spread graphite during assembling.
5.5.4 All ring block should be clean and free from distortion. Put them into groove with clearances
to upper and lower side of 0.5mm; put six-element ring into groove with same height above.
5.5.5 Valve with starting seat vertically up and down, its upper section should cooperate with guide
sleeve well and free from block with clearance of 0.3-0.5mm.
5.5.6 Swing check valve and connection of its clack and fixing end should be agile and reliable;
lifted valve clack can drop freely under force of gravity, sealing between valve clack and valve
clack sealing surface is good and free from seeable clearance.
5.5.7 Using stuffing should comply with requirements of working medium. Sealing stuffing should
ensure its total height. Stuffing pressing ring should be agile after slipping into valve cover and free
from block to ensure its compaction to stuffing. Connection of replaced sealing stuffing should be
chopped in 45, connections of all rings should stagger 90-120, the length of cut stuffing should
be proper and connections of stuffing can not be with clearance or folding.
5.6 Vessel overhaul quality standard
5.6.1 Safety valve action should be agile and reliable, its test action value should comply with
requirements and all parts are free from leakage.
5.6.2 Water level indicator is clear, steam water valve switch is agile and mica stuffing sealing
has no leakage.
5.6.3 Pressure meter indications are right and they are qualified after calibration.
5.6.4 Steam and water exhausting valve should be agile, strict and free from leakage.
5.6.5 Vessels after repair should be clean and free from rust; repair welding should be done for all
corrosion points and crackles. Separation blades of separation device should be complete and fine
with even clearance and free from rust, corrosion. Welding part should be free from leakage.
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5.7 Steam water pipeline overhaul quality standard
5.7.1 Pipes put on fixing bracket pipe clip should be fixed, clip hook should be tight; suspending
and supporting pipe clips must made from alloy materials to avoid decarbonization and crackles.
5.7.2 Moving supporting frame should not influence free displacement of pipes and moving parts
should be free from block and deflection.
5.7.3 Ball bearing and shaft neck of its suspending frame should be free from block.
5.7.4 Ball bearing and its supporting surface and moving plane should contact tightly with no
clearance and be free from block.
5.7.5 Spring compression of spring suspending frame is able to be regulated, pretightening force
of spring supporting frame should comply with requirement of drawings.
5.7.6 Fixing end of suspending frame should be reliable; suspending stem should be vertical to
pipes.
5.7.7 Suspending and supporting spring surfaces should be free from crackle and delamination,
tolerance of spring dimension should comply with requirement of drawings, error of spring working
rings should not exceed half ring. Under free condition, pitch of al rings of spring should be even
and its error should not exceed 10% of average pitch. Supporting surfaces at two ends of spring
should be vertical to spring axes and its error should not exceed 2% of free height.
. Requirements of Safety, Health and Environmental Protection

6.1 Safety
6.1.1 Safety belt should be tied well for high altitude work, build scaffold and protective fence well,
check carefully whether scaffold is firm or not before starting work.
6.1.2 Exposure suit should be worn during safety valve test.
6.1.3 Check before using lifting tools, which can be used only after it is conformed that there is no
any danger.
6.1.4 Communication should be smooth during safety valve test, all joined personnel should be
careful.
6.1.5 After dismantling valve, all tools and dismantled parts should be cleared up; protective
measures should be taken for dismantled valves to avoid impurities.
6.1.6 Safety helmet, enclosure suit and working shoes should be well worn during high altitude
work and supervision also should be done well; materials, spare parts should be put at reliable
place.
6.1.7 During repair of running equipments, steam and water scald should be avoided; work can
only be started after confirming that equipment in maintenance is completely isolated from running
equipment.
6.1.8 Creepage, electric shock should be avoided during using electric-driven tools, scrap iron
may hurt your eyes when using electric-driven grinder; check electric-driven tools and protective
glasses should be worn when using electric-driven tools such angle grinder.
6.1.9 During welding in replacing valve, electric sparkles should be avoided to drop in cable slot
which may cause fire.
6.2 Health
6.2.1 Measures for preventing heatstroke should be done well when working in high working
environment temperature.
6.2.2 Protective measures should be done well for high temperature objects near working site to
prevent working personnel from contacting the high temperature objects.
6.3 Environmental protection
6.3.1 After work is completed, heat insulation should be done well for high temperature valves to
55
ensure that environment temperature does not exceed related requirements in specifications.
6.3.2 After work is completed, clean the site and ensure neatness at working site.
7. Twenty Important Anti-Accident Measures

7.1 Boiler over pressure hydraulic test and safety valve setting should be executed according to
regulations.
7.2 Special safety technical measures should be made for over pressure hydraulic test of large
capacity boiler and hot state safety valve calibration to avoid overpressure or over temperature
due to too fast pressure rise, losing control of pressure or steam temperature.
7.3 Test non-related personnel is prohibited to enter into site during boiler overpressure hydraulic
test and hot state safety valve setting.
7.4 Strengthen inspection of pipe socket welding line, inner wall erosion and appearance corrosion
of small diameter pipes of HP & IP drainage water, blowdown, attemperating water in steam water
system; change it if any problem is found.
7.5 Check suspending and supporting frames periodically. Completely check and regulate
suspending and supporting frames of main steam pipeline and reheating steam pipeline with
running time of 100kh and more, stress calculation should be done if it is necessary.
7.6 For the drainage water and air pipelines that may cause steam water two phase flow, their
inner hole circumference, elbow of angle welding line and header openings connecting with
header should be emphatically checked and it is better to change them after 100kh running time.
Any maintenance work or tightening is prohibited when there is pressure inside pressure vessel.
7.7 Pressure meters on pressure vessel should be listed and checked as forceful check meters
and should be checked forcefully according to regulations periodically.
7.8 Combined with periodic inspection and maintenance of pressure vessels, at least one
pressure resistance test should be done in two inspection cycles.
7.9 Flange connection should be avoided as much as possible in oil system, iron casting valves
are prohibited.
7.10 Plastic gasket, rubber gasket (including oil resistant rubber gasket) and asbestos gasket are
prohibited for flanges in oil system.
7.11 Fire is prohibited near oil pipeline flanges, valves and possible oil leakage parts, effective
measures should be taken if fire must be used for working, insulations of pipelines nearby and
other bodies should be complete and fixed and enclosures by iron sheet.
7.12 Welding is prohibited in oil pipelines; pipe should be cleaned before dismantling for welding.
7.13 Oil pipeline flanges, valves and bearing, speed regulation system should be strict and free
from oil leakage, it should be cleaned in time if there is oil leakage, leaked oil is prohibited to seep
to lower steam pipe and valve insulation layer.
7.14 If there is thermal pipeline or other thermal bodies under or around oil pipeline flanges or
valves, insulation of these hot bodies must be complete and enclosures by iron sheet.
7.15 If oil leakage is found in insulation material during maintenance, oil leakage points should be
cleaned and insulation material should be changed.
7.16 Two steel check valves are installed for emergency oil valve, their operation hand wheel
should be 5m away from oil tank and it should be with more than two channels. Lock is not allowed
for operation hand wheel and sign plate of No Operation should be hung for hand wheel.
7.17 Oil pipeline should ensure free expansion of the unit under all kinds of working conditions.
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Chapter Maintenance of Burner and Oil Gun
. General
1.1 Applicable scope: This chapter of maintenance regulation is applicable to boiler burner, oil gun
and its accessories of Indonesia Paiton 1660MW coal fired thermal power plant.
1.2 Quoted materials:
Related materials of Harbin Boiler Company Limited
. Equipment Basic Conditions and Parameters

Burning system of the boiler consists of SOFA burner (including NO1, NO2, NO3, NO4), big
air box (two), boiler front oil system, high energy igniter and ignition oil gun etc.
2.1. SOFA burner:
The design of SOFA coal powder burner has considered the adaptability of design coal and
check coal within permit change range of coal quality. High quality, heat resistant stainless plate
ZG30Cr22Ni7Si2NRe, heat resistant temperature of which reaches to be more than 1050, is
adopted for nozzles to prevent primary air nozzles from burning or abrasion. Heat resistant cast
steel has a good wear resistance, which can meet the requirement that service life of nozzles of
burner is no lower than 50000 hours. Coal powder spray pipe connects with primary air pipe and
can be taken out from burner air box conveniently for dismantling, reinstalling and repair outside,
which makes the maintenance of primary air nozzles be done conveniently and quickly.
Dismantling and reinstalling outside during maintenance should be considered for structure design
of burner.
Swing burners are adopted and in foursquare tangential arrangement; during hot state
operation, both primary and secondary air nozzles can swing up and down with designed swing
angles, maximum swing angle of primary air nozzle is 27 and maximum swing angle of primary
air nozzle is 30. Nozzle swing is realized by air-driven actuator which has sufficient moment to
make burners swing neatly and synchronously. Swing angle indication and mechanical position
limit device are set on burners. Control indication and position feedback signal of actuator are 4
20mADC. Burner can expands neatly and be with no block.
The arrangement and design of burner is confirmed through modular test and symmetric
combustion is adopted. There is sufficient distance from center line of upper row primary nozzle to
bottom of panel superheater and from down row primary air nozzle center line to syphon of cold
ash hopper. There is no flame eroding cooling water wall or obvious coking and there is no
obvious coking near burner outlet and cooling water wall to ensure safe and economic operation of
the boiler. Measures for decreasing NOx in burning products and measures for stabilizing
minimum load without oil are considered in design and arrangement of burners.
Flange connection is adopted for burner and cooling water wall, their structure design can
ensure normal expansion difference movement between burner and cooling water wall and ensure
that there is no air leakage. In operation working condition, burner expands downwards with
cooling water wall.
Measures preventing ripping cooling water wall pipe due to hot load and different pipe lengths
are taken for cooling water wall fin at four corners of burner.
Secondary air damper switch of burner is rightly in position and every air valve can regulate
automatically. Total heat input of oil burner is calculated as per 20% B-MCR. Ignition system can
meet program control and ignition manner is to ignite light oil with high energy electric spark and
then ignite coal powder. Fuel oil adopts steam atomization and nozzles ensure a good fuel
atomization and complete combustion. It should be avoided that fuel oil drops to boiler button or is
brought to tail gas duct.
57
Fuel oil system consists of ring oil supply head pipe, ring oil returning head pipe, ring
compressed air head pipe for purging, branch pipes from head pipes to oil guns, high energy
igniter and its driven devices, connection metal tube, oil angle valve, purging valve, regulation
valve, quick-closing valve of returning oil supplying head pipe, oil gun and accessories.
Burner design data (as per THA working of designed coal)
Item Unit Value
Primary air temperature 80
Secondary air temperature 330
Mill inlet air temperature 307
Primary air speed m/s 28

Secondary air speed m/s 48
Primary air rate % 70
Secondary air rate % 25
Coal powder particle size R90 % 22
Mill running set 5
2.2 Air box
Partition big air boxes are adopted for the boiler to improve economy of combustion and
decrease NOx discharging amount. There are two partition big air boxes at front and rear wall
respectively, which distribute air for second layer burner and first layer burner and NOx nozzles on
them. The figure dimension of air boxes are 9100206902440mm3 and 7225206902440mm3
height width thickness respectively. There are two motor-driven regulation dampers of
secondary air distribution channel at both two sides of every air box, and there are airfoil speed
measuring device in secondary air distribution channel. Regulating air amount can meet the
requirement of best combustion by regulating openness of secondary air distribution channel
damper, which makes air amount to every layer burner proper to coal powder amount entering this
layer from corresponding coal mills. When some burner and its matching coal mill stop, air inlet
damper of this partition bin should be regulated to Cooling position (at this time, air inlet amount is
about 25% of air amount in normal operation) to cool the stopped burner. Air distribution channel
motor-driven regulation damper at to sides of NOx nozzle can control the start and cooling of NOx
nozzle.
The arrangement of partition air box can make the hot power of burners at all layers and load
of coal mills different, which makes it available for the operators to regulate heat transferring in
boiler according to actual combustion in furnace and control the steam temperature.
2.3 High energy ignition device
One set high energy ignition device is set for every burner and make the burner available to
ignite automatically; high energy ignition device mainly consists of ignition exciter, ignition stem,
ignition cable, semiconductor spark plug, and ignition oil gun and propulsion device. Propulsion
device has two cylinders, which bring ignition stem and ignition gun to realize advance and retreat.
The working pressure of cylinder is 0.40.6MPa and its journey is 400mm. The cylinder controls
speed of advance and retreat of piston with single direction throttle control valve. Adjacent switch
sends messages when ignition oil gun and ignition stem advance and retreat to position.
Exciter input power: AC220V10%; 50Hz
AC current 35A
Exciter output power: Single time energy storage 20J
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Spark discharge frequency: 1015 times/second
Semiconductor spark plug catching fire voltage: 2500V
2.4 Oil gun
One ignition oil gun is set for every set high energy ignition device for ignition, warming up
boiler, increasing pressure and coal powder burner for burning and stabilizing combustion.
Mechanical atomization is adopted for the oil nozzles in this boiler. Total heat input of thirty six (36)
oil funs of the boiler is about 20% of boiler B-MCR heat input.
Related technical data of oil nozzles is as following:
Output Working oil pressure Engler viscosity
Kg/h MPa E
800 2.5 <3
2.5 Boiler front oil system:
There are quick-closing valve, flow indicator and pressure detection point on boiler oil
supplying head pipes, on which there are quick-closing valve, returning oil regulation valve and
pressure detection points. Oil supplying pressure (2.5MPa) during ignition by control oil gun is
controlled by regulating returning oil regulation valve openness to ensure successful ignition. Oil
system of the boiler adopts one controls one, namely oil supplying of one oil gun is controlled by
one air-driven ball valve; meanwhile, steam soot blowing also adopts one controls one, namely
one air-driven ball controls one oil gun. Manual check valve and manual stop valve are set on
every oil gun oil pipeline and steam soot blowing pipe line, motor-driven stop valve is set on soot
blowing general pipeline.
. Maintenance Item
3.1 Major maintenance items
3.1.1 Repair and change nozzles of burner
3.1.2 Repair and change lamina of burner
3.1.3 Change gland packing at connections of burner and cooling water wall
3.1.4 Repair air regulation damper of burner
3.1.4 Check and change burner inlet elbow
3.1.5 Check and change burner sprinkler and distributor
3.1.6 Repair oil gun
3.1.7 Repair oil system
3.1.8 Repair secondary air box and inlet expansion joint
3.1.9 Repair flame detection cooling air fan
3.2 Minor maintenance items
3.2.1 Check burner
3.2.2 Check secondary air damper
3.2.3 Check secondary air box
3.2.4 Repair oil gun
3.2.5 Repair oil system
3.2.6 Change flame detection cooling air fan outlet damper
3.2.7 Check and change cathode and anode of plasma burner
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3.2.8 Repair valve and filter of plasma burner system
. Maintenance Process, Process Method and Quality Standard

4.1 Preparation
4.1.1 Confirm important maintenance technical plan and technical measures arrangement and
abrasion or damage degree of all parts according to running condition and technical records of
previous maintenance.
4.1.2 Spare parts should be prepared in advance to ensure parts can be changed timely in
maintenance.
4.1.3 Prepare all kinds of maintenance special tools, general tools and measures.
4.1.4 All lifting devices, tools should be tested and checked according to regulation.
4.1.5 Construction power supply, lamps and lanterns and illumination power supply should be
arranged at construction site, scaffold should be built at the same time with maintenance of
cooling water wall.
4.1.6 Floor plan of equipment parts should be set during maintenance.
4.1.7 A complete set of recording tables and cards should be prepared.
4.1.8 Clean site, arrange special location for arranging required parts, dismantling and main parts
according to floor plan.
4.1.9 Mechanical work permit ticket should be issued.
4.2 Process and Methods
4.2.1 Repair and change nozzles
4.2.1.1 Check damage condition by burning of nozzles.
4.2.1.2 Burner with biggish damaged part by burning should be changed.
4.2.2 Secondary air damper maintenance
4.2.2.1 Revise secondary air damper, figure and straightness.
4.2.2.2 Check agility of secondary air damper action and whether switch is in right position or not,
whether actual openness and local indication comply or not; if they do not comply, journey should
be regulated again.
4.2.3 Burner lamina maintenance
4.2.3.1 Open air box and check burner laminae, especially the bottom.
4.2.3.2 Serious abrasion of repair welding should be changed.
4.2.4 Change gland packing at connections of burners and cooling water wall.
4.2.4.1 Check whether gland packing at connections of burners and cooling water wall are aging
or not.
4.2.4.2 Change aged high temperature asbestos rope.
4.2.5 Burner air regulation damper maintenance
4.2.5.1 Check all the air regulation dampers whether they have distortion, dropping and loosening
or not; repair it if there is.
4.2.5.2 Check the openness of air regulation air dampers; it should be regulated if they are not
consistent.
4.2.6 Secondary air box maintenance
4.2.6.1 Check whether manhole valve of air box is distorted or damaged or not, repair it according
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to condition if there is and the dropped bolts should be supplemented. Check whether gland
packing of air box manhole is aged or not, change it if it is aged.
4.2.6.2 Check whether air box has ash leakage or not and expansion condition.
4.2.6.3 Check whether ripple expansion joint is distorted and damaged or not and whether welding
points have defect or not; repair according to condition.
4.2.6.4 Check insulation conditions of all parts.
4.2.6.5 Check force bearing conditions of all supporting seats, steel beam and angle steel.
4.2.7 Flame detection cooling air fan maintenance
4.2.7.1 Clean screen of flame detection air fan.
4.2.7.2 Check reversing damper outlet of flame detection air fan and change rubber skin of
dampers.
4.2.7.3 Dismantle air box shell, take off impeller, check conditions of abrasion and distortion of
current collector, shell and impeller and welding line; repair it if there is.
4.2.7.4 Reinstall all parts of cooling air fan.
4.2.7.5 Air fan trial run: it is deemed as to be qualified that air pressure higher than 7.0KPa and air
fan free from abnormal sound is deemed as qualified.
4.2.8 Oil gun maintenance
4.2.8.1 Dismantle oil gun, check and clean oil splitters and atomization angles of oil gun.
4.2.8.2 Dismantle oil gun sleeve, check whether there is friction between oil gun and sleeve or not.
4.2.8.3 Check whether there is block at oil gun cover or not, clean it if there is.
4.2.8.4 Check gland packing for sealing between sleeves.
4.2.8.5 Check whether oil gun cylinder is agile or not and whether there is air leakage or not.
4.2.8.6 Check whether there is dilapidation at tube of oil gun or not, change it if there is.
4.3 Quality standards
4.3.1 Nozzles Overhaul Quality Standard
4.3.1.1 All nozzles are smooth and free from damage, distortion or burn
4.3.1.2 Steels and welding materials should be right.
4.3.1.3 Installation dimension, angle should be right as per drawings.
4.3.2 Secondary Air Damper Overhaul Quality Standard
4.3.2.1 Dampers should be free from serious abrasion and distortion.
4.3.2.2 Open and close to right position, damper openness is consistent with indication.
4.3.3 Burner Vanes Overhaul Quality Standard
4.3.3.1 Burners vane should be free from abrasion and distortion.
4.3.3.2 Burner vane shaft should be free from abrasion.
4.3.3.3 Burner vane installation direction should be right.
4.3.4 Oil Gun Overhaul Quality Standard
4.3.4.1 Metal tubes of all parts of oil gun are free from damage and assembled as per
requirements.
4.3.4.2 Advancing and retreating of oil gun brought by air cylinder is agile and free from block.
4.3.4.3 Gun head and gun pipe are connected tightly.
4.3.4.4 Diffusion cover is free from block.
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4.3.4.5 Oil splitters and atomization angles are free from block.
4.3.5 Oil System Overhaul Quality Standard
4.3.5.1 There is inner or outer leakage at valves.
4.3.5.2 All the pipelines are free from block and leakage.
4.3.5.3 Solenoid valve can be opened or closed freely.
4.3.6 Burner Air Box Overhaul Quality Standard
4.3.6.1 All holes and valves are strict and no bolts are missed; welding can not be done instead of
bolts fixing.
4.3.6.2 Expansion is free and insulation is fine and complete.
4.3.7 Flame Detection Air Fan Overhaul Quality Standard
4.3.7.1 Air blades turn freely and free from abrasion and swinging.
4.3.7.2 Sieve is clean; sponge cover should be replaced periodically.
4.3.7.3 Outlet non-return damper of air fan should turn freely, rubber should be changed
periodically and its quality should be ensured. Make sure that there is no impurity on damper.
4.3.7.4 Motor of air fan should be filled oil periodically, and its vibration should not exceed standard
value.
4.3.7.5 Anchor bolts and bolts of shell are not loosened and tightening stress is even.
. Safety, Health and Environmental Protection Requirement

5.1 Safety
5.1.1 Working suits and safety protective articles should be worn according to Safety Rules when
entering into site.
5.1.2 One principal must be conformed when two or more than two personnel are working.
5.1.3 Sufficient lighting should be prepared at site and complies with Safety Rules.
5.1.4 Creepage protector must be used when using electric tools and regulations for using electric
tools must be complied. Tools or apparatus with defects can not be used.
5.1.5 Fire must be avoided when cleaning or filling oil tank. Gasoline is prohibited to clean parts.
5.1.6 Safety belts, tools must be rightly used when working at high altitude, transportation of
materials should comply with Safety Rules.
5.1.7 Comply with Safety Rules of lifting and conveying carefully.
5.1.8 Recover the shield, protective cover and groove cover plate that dismantled during overhaul
after work is completed.
5.1.9 Check and amount personnel and tools after work, reclaim residual materials, clear up
kindling and clean the working site.
5.1.10 Clear up flammable and explosive impurities at site.
5.1.11 Electric welding earth wire is on parts to be welded, long distance loop is not allowed.
5.1.12 Sufficient fire-fighting apparatus should be prepared at site.
5.1.13 Special person should be sent for supervision when there is work with fire.
5.1.14 Clean the site after work is completed and no kindling is left.
5.2 Health
5.2.1 Protection measures must be done when touching poisonous, deleterious chemicals or
chemicals with pungent smell.
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5.2.2 Ventilation equipments must be supplied for vessels or air boxes to avoid asphyxiation when
personnel are working in boxes.
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Chapter Soot Blower Maintenance
. General
1.1 Applicable scope: This chapter of maintenance regulation is applicable to soot blower devices
of Indonesia Paiton 1660MW thermal coal fired power plant.
1.2 Quoted materials: this chapter of maintenance regulation quotes related materials of Hubei
Diamod Machine Co. Ltd.
. Equipment Brief Introduction and Parameters

2.1 Brief introduction
For cleaning slag and accumulated ash on heating surface, soot blowing system is set for the
boiler with 70 soot blowers in furnace, 64 long soot blowers and 2 soot blowers for each air
preheater. All the soot blowers adopt steam for soot blowing; steam source comes from panel
superheater outlet header, and steam source comes from auxiliary steam at initial starting.
See as equipment parameters in steam parameters table.
2.2 Maintenance process and quality standard
2.2.1IR-3D soot blower maintenance
2.2.1.1 Goose neck valve maintenance
2.2.1.1.1 Dismantle two pins of startup arm and take off startup arm.
2.2.1.1.2 Press down valve spring with special tool and take off valve stem clip.
2.2.1.1.3 Take off spring pressing cover and spring, screw off stuffing nuts.
2.2.1.1.4 Take out stuffing pressing ring and old stuffing.
2.2.1.1.5 Demount bolts and nuts at connections of goose neck valve and inner pipe and steam
pipeline flanges, take off body valve, block the steam pipeline flange with block plate to avoid
impurities dropping into it.
2.2.1.1.6 Demount valve stem, valve clack and other parts; remember position of pressure
regulation plate to ensure right assembling.
2.2.1.1.7 Check corrosion and erosion degree of valve stem surface inside and outside valve body
and upper and lower interface. Different methods should be adopted according to different
corrosion degree, see as the quality standard in detail in Pipeline Vavle Overhaul Technics
Specification.
2.2.1.1.8 Check spring that should free from distortion and crackles.
2.2.1.1.9 Check working surface condition of flanges and clean the defects, it should be free from
radial groove.
2.2.1.1.10 Reassembling process is just opposite to dismantling, and pays attention that:
2.2.1.1.10.1 Force should be even for tightening flange bolts which should be tightened on the
cross.
2.2.1.1.10.2 Ceruse grease should be plastered on screw thread part.
2.2.1.1.10.3 Gland packing cut should be 45O and tangents at two ends should be parallel, length
of which can be pressed into stuffing box in level. Connections should be free from clearance and
superposition. Cut of two rings should be staggered 90O-180O; 1.5-2 mm ceruse should be
plastered evenly in middle of gland packing.
2.2.1.2 Gear reducer overhaul
2.2.1.2.1 Glide shaft-end connection sleeve forwards and show up straight pin.
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2.2.1.2.2 Take off straight pin.
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Soot blowers and steam parameters
Equipment Nozzle Min. Min. Journey Spiral Time (min) Steam consumption (Kg) Remark
pres pres guide
sure sure journ
after befor ey
valve e (mm)
Model Serial Qty Qty Calib (Mpa valve Total Soot Speed Singl Singl Total Cons Single Total in
No. er ) (Mpa journey blowing (M/min e e in umpt set this
(mm) ) (mm) journey ) soot runni this ion/ consu column
(mm) blowi ng colu min mption
ng time mn
time
IK-545 1-4 4 2 28.6 1.36 1.48 10200 9895 2.5 100 7.92 8.16 32.6 87 689 2756 1Cr18Ni9Ti
IK-545 5-24 20 2 28.6 1.28 1.4 10200 9895 2.5 100 7.92 8.16 163 87 689 13780 30Cr1MoV
IK-545 25-40 16 2 25.4 1.15 1.23 10200 9895 3.5 100 5.65 5.83 93.3 69 390 6240
IK-545 41-64 24 2 22.2 0.83 0.87 10200 9895 3.5 100 5.65 5.83 140 43 243 5832
2
IR-3D 1-70 70 1 25.4 1.40 1.54 360 1 circle 2.5rpm 0.43 2.83 198. 66 28 1960
1
TP-50 1-2 2 7000 3 4.7 9.4
0
IK-AH 1-4# 2 7 12-1 1.0 1.03 850 800 0.9 ------- 23 24 96 55 1265 5060
Steam gun
gas 6
inlet
2 7 10 0.50 0.52 850 800 0.9 ------- 44 45 180 705 31020 124080 Water gun
5-8# 2 7 12-1 1.0 1.03 850 800 0.9 ------- 23 24 96 55 1265 5060
Steam gun
gas 6
outlet
2 7 10 0.52 0.54 850 800 0.9 ------- 44 45 180 705 31020 124080 Water gun
Total: 140 sets, among which IK-545 is 64sets; IR-3D is 70 sets; TP-500 is 2 sets and IK-AH is 4 sets.
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2.2.1.2.3 Demount fixing stud bolt of gear box and installation frame.
2.2.1.2.4 Take off motor control box and gear reducer.
2.2.1.2.5 Dismantle gear box, clean inner worm wheel and check abrasion.
2.2.1.2.6 Demount big and small gear box in control box and check abrasion.
2.2.1.2.7 Reassemble in opposite procedure.
2.2.1.3 Drive pin overhaul
2.2.1.3.1 Dismantle fixing screw and gasket of drive pin.
2.2.1.3.2 Screw M3 bolts into center hole of drive pin, pull out drive pin by clipping bolt with pliers.
2.2.1.3.3 Check and change drive pins with serious abrasion.
2.2.1.3.4 Reassemble drive pin, pay attention that: drive pin should inosculate groove, screw
should not be too tight and gasket should not bend.
2.2.1.4 Spray nozzle
2.2.1.4.1 Dismantle whole soot blower and block steam pipe with angle flange.
2.2.1.4.2 Grind welding points of screw thread pipe and spray nozzle with portable grinding
machine, screw off the spray nozzle.
2.2.1.4.3 Check erosion to inner diameter of spray nozzle and spray orifice, change it if it exceeds
requirement; erosion of inner diameter surface should not exceed 10%.
2.2.1.4.4 Reassembling. Pay attention that spot welding should be done after screwing spray
nozzle to original position.
2.2.1.5 Repair small gear bearing, front big gear and front big gear bearing.
2.2.1.5.1 Dismantle motor and control box.
2.2.1.5.2 Pull out small gear for check and cleaning.
2.2.1.5.3 Demount gear cover.
2.2.1.5.4 Demount spray nozzle and drive pin.
2.2.1.5.5 Demount seat plate of guide stem.
2.2.1.5.6 Take off supporting seat and gear.
2.2.1.5.7 Find out bearing closing ring openness and prize closing ring from groove, turn the big
gear in clockwise and take closing ring out.
2.2.1.5.8 Take out gear and bearing out from supporting seat and then take out bearing closing
ring to separate bearing from gear.
2.2.1.5.9 Check abrasion of gear and bearing, change the ones that do not comply with
requirement, abrasion of gear end should not exceed 1/3 and bearing should be free from
breaking and crackle.
2.2.1.5.10 Clean gear bearing and lubricate it.
2.2.1.5.11 Check whether supporting parts are in fastness or not.
2.2.1.5.12 Reassemble it in reversal sequence of dismantling.
2.2.1.6 Check screw thread pipe and inner pipe
2.2.1.6.1 Pull out front supporting and screw thread pipe subassemblies from ends of inner pipe.
2.2.1.6.2 Check screw thread pipe surface and clean dirties inside and outside.
2.2.1.6.3 Demount flange bolts of inner pipe and dismantle inner pipe.
2.2.1.6.4 Check flange sealing surface of inner pipe, which should be free from radial groove.
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2.2.1.6.5 Check whether polishing on surface of inner pipe has damage or not.
2.2.1.6.6 Reassembling. Change stuffing inside inner pipe during reassembling. Pay attention to
following problems:
2.2.1.6.6.1 The sealing gasket at outlet of goose neck valve can be used continuously of it is not
damaged; take it off carefully if it is necessary to change, clean the sealing surface and sharp tools
can not be used to scrape sealing surface.
2.2.1.6.6.2 Install inner pipe, a layer of high temperature grease must be plastered when screwing
bolts with hand.
2.2.1.6.6.3 Even force (torque: 40Nm) should be used across screwing bolts, otherwise angle
error may be produced in inner pipe, which may influence normal working of soot blowers.
2.2.1.7 Lubricating
2.2.1.7.1 #460 gear oil should be used for idler wheel, ratchet, worm wheel gear box and thrust
bearing at two ends of gear box.
2.2.1.7.2 Lubricate front supporting seat bearing with high temperature grease.
2.2.1.8 All regulations and notes
2.2.1.8.1 Regulation of nozzle pressure
2.2.1.8.1.1 Demount lock screw of pressure regulation plate.
2.2.1.8.1.2 Dial gear of pressure regulation plate with screwdriver for regulation.
2.2.1.8.2 Regulation of control actuator
2.2.1.8.2.1 Cut off power supply.
2.2.1.8.2.2 Demount control box cover and show up regulation gear.
2.2.1.8.2.3 Demount pin gasket of biggish gear, separate gear outer teeth from 15-teeth-gear.
2.2.1.8.2.4 Waggle manual crank anticlockwise and make screw thread pipe extend to front limit
position and open the valve, top of starting arm lie in the middle guide notch (other points are best
reverse point).
2.2.1.8.2.5 Turn big gear manually clockwise and make it strike journey switch at left side and
send a rattling sound, front thrusting big gear joggles with 15-gear-gear.
2.2.1.8.2.6 Waggle soot blower to original position.
2.2.1.8.2.7 Send power and it runs automatically.
2.2.1.8.3 Nozzle front and rear position regulation
2.2.1.8.3.1 Move the two inner regulation nuts forward in the distance same with nozzle has
moves forwards.
2.2.1.8.3.2 Screw down out regulation nuts to make flange between cam and stuffing room tighter
until it tightly leans against inner regulation nuts, thus the screw threads and nozzles can insert
into boiler deeper.
2.2.1.8.3.3 Screw down inner and outer regulation bolts.
2.2.1.8.3.4 Regulate motor control device again.
2.2.1.8.3.5 Operation of backward move is just opposite to above.
2.2.2 IK545 soot blower overhaul
2.2.2.1 Valve and valve open & close actuator overhaul
2.2.2.1.1 Draw out outer end of connection stem of valve and running car, pins of valve top, valve
stem and connection stem. Specific quality standard refers to Technical Code for Overhaul of
Pipelines and Valves.
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2.2.2.1.2 Screw off the four bolts connecting with inner pipe at outlet of valve and the nuts of six
bolts of incoming steam flange; supporting vertical plate of valve body should not be dismantled to
avoid position change during assembling.
2.2.2.1.3 Take off valve body, demount valve clack of valve stem and other devices; position of
pressure regulation plate in valve body and clearances of all moving parts should be recorded for
right recover during reassembling.
2.2.2.1.4 Check valve body that should be free from sand hole and erosion.
2.2.2.1.5 Check corrosion and erosion of valve stem, valve clack and valve seat and treat it
according to actual condition.
2.2.2.1.6 Check sealing condition of all sealing surfaces, clean or change it if erosion is found.
2.2.2.2 Sealing stuffing device overhaul
2.2.2.2.1 Waggle running car several centimeters forwards to get bigger space.
2.2.2.2.2 Demount nuts of stuffing pressing cover and slip pressing cover to rear section of inner
pipe.
2.2.2.2.3 Hook old stuffing with packing hook and avoid to damage inner pipe surface.
2.2.2.2.3.1 Clean stuffing box, pressing cover and all parts carefully.
2.2.2.2.3.2 Check inner wall and stuffing box, there should be no big nick or abrasion on inner wall
and in stuffing room.
2.2.2.2.3.3 Install flexible graphite packing, specific quality standard see as in Technical Code for
Overhaul of Pipelines and Valves and Installing Valve Stem Gland Packing.
2.2.2.3 Inner and Outer Sleeve Overhaul
2.2.2.3.1 Demount four M20 nuts and two M10 bolts on flange of inner pipe, push inner pipe flange
forwards and take out key.
2.2.2.3.2 Push inner pipe forwards and demount inner pipe stuffing.
2.2.2.3.3 Push inner pipe into stuffing box.
2.2.2.3.4 Hold soot blower with manual hoist or other tools, demount six fixing bolts, move soot
blower gun forwards at flange to make inner pipe separate from running car and then put it down.
2.2.2.3.5 Check inner & outer pipe surfaces and all screw threads, whether there is damage,
abrasion or not, repair or change it if there is. Polishing of inner pipe surface should be free from
damage or trace.
2.2.2.4 Running car dismantling and check
2.2.2.4.1 Dismantle inner and outer pipe.
2.2.2.4.2 Take off limit switch on box upper section of running car, draw out the pin.
2.2.2.4.3 Demount rear cover plate, suspend running car, dismantle two short cuttings at rear end
of lower beam and supporting angle steel of running car, and lay down running car.
2.2.2.4.4 Dismantling of running car is divided into seven steps:
2.2.2.4.4.1 Motor and motor gear box
2.2.2.4.4.1.1 Dismantle 1/2 screw plug at bottom of running car box and screw bolt at bottom of
motor gear box, discharge oil completely.
2.2.2.4.4.1.2 Take off six M10 bolts and pull motor and motor gear box backwards.
2.2.2.4.4.1.3 Clean inner gear and check its joggling and abrasion. Gear should be free from
crackle and serious abrasion.
2.2.2.4.4.1.4 Check springs of all seals, check whether sealing of closing rings, sealing surfaces
and sealing gaskets comply with requirements or not.
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2.2.2.4.4.1.5 Check fixing condition of motor gear and motor fastness, worm wheel and closing
rings; repair or change it if it is damaged.
2.2.2.4.4.2 Stuffing box bearing and bevel gear
2.2.2.4.4.2.1 Dismantle 1/2 screw plug at bottom of box and at bottom of stuffing box, discharge oil
completely.
2.2.2.4.4.2.2 Demount stuffing pressing cover and flanges from stuffing box.
2.2.2.4.4.2.3 Demount four M16 bolts of front end; demount bearing pressing cover and gasket
from running car box.
2.2.2.4.4.2.4 Take out stuffing box, bearing and bevel gear as a whole from running car box.
2.2.2.4.4.2.5 Demount four M16 bolts of rear cover, demount bearing pressing cover, gasket and
bearing from the other side of running car box.
2.2.2.4.4.2.6 Check whether sealing ring edge of bearing cover has damage and distortion or not.
2.2.2.4.4.2.7 Demount small bevel gear, check abrasion and distortion of all parts, clean oil dirties
of all parts.
2.2.2.4.4.2.8 Check bearing condition.
2.2.2.4.4.3 Main shaft and spur gear
2.2.2.4.4.3.1 Demount drive small gear.
2.2.2.4.4.3.2 Demount cover of running car box.
2.2.2.4.4.3.3 Demount closing ring in lifting ear of box shell.
2.2.2.4.4.3.4 Prop up closing ring and slip to end of keyway along shaft, closing ring should not be
propped too much, which may cause distortion.
2.2.2.4.4.3.5 Beat stuffing box side of running car slightly with rawhide hammer to make main shaft
out; outer end bearing, oil sealing, inner side, bearing and key separate from gear together when
shaft is demounted; Before shaft end separate from gear, closing ring should be taken off timely to
avoid dropping into box bottom of running car.
2.2.2.4.4.3.6 Clean all the oil dirties in gear bearing and box; check whether connection, drive and
abrasion comply with requirements or not, it should be repaired or changed if it does not comply.
2.2.2.4.4.4 Trolley and drive small gear of running car
2.2.2.4.4.4.1 Demount drive small gear from two ends of main shaft after taking off closing ring.
2.2.2.4.4.4.2 Demount closing ring, take off ball bearing.
2.2.2.4.4.4.3 Clean oil dirt at all parts, check bearing status, bearing should be lubricated and
protected in advance and no more lube is needed.
2.2.2.4.4.4.4 Check whether small gear has abrasion or not.
2.2.2.4.4.5 Worm, worm wheel, spur gear and bearing box
2.2.2.4.4.5.1 Dismantle 1/2 screw plug at bottom of box of running car, discharge oil completely.
2.2.2.4.4.5.2 Demount four M8 bolts, take out shaft, bearing, spacing ring and bearing pressing
cover as a whole and then dismantle them into parts.
2.2.2.4.4.5.3 Check bearing, worm gear and oil sealing, repair or change them if any is found
damaged.
2.2.2.4.4.5.4 Demount six bolts of fixing bearing box; take out worm wheel, spur gear, shaft and
bearing as a whole and then dismantle them into assembled fittings. Clean all oil dirty, check
abrasion of all parts; remember that all parts can only be demounted from screw threads of shaft.
2.2.2.4.4.5.5 Demount bolts, pressing cover and lock nuts; and then dismantle al parts on shaft.
70
2.2.2.4.4.5.6 Check abrasion and crackle of bearing, oil sealing, gear and worm wheel gear,
especially abrasion at copper worm wheel; repair or change it if there is any defect.
2.2.2.4.4.6 Spiral line phase transformation actuator overhaul
2.2.2.4.4.6.1 Move running car forwards manually about 15cm.
2.2.2.4.4.6.2 Dismantle bolts, nuts and spring gaskets from fixing phase transformation actuator to
beam; take off phase transformation actuator.
2.2.2.4.4.6.3 Clean racks, gear and oil dirty at all parts; and check whether there is joggling,
distortion and crackle or not.
2.2.2.4.4.6.4 Check screw threads at all parts, check whether fixing device is complete and fine or
not, otherwise defect should be cleaned.
2.2.2.4.4.7 Check whether nozzles are smooth or not, whether caliber is eroded to be bigger or
distorted or not. Nozzle should be free from block or distortion and abrasion of spraying orifice
does not exceed 10%, steam flow angle should be right.
2.2.2.4.4.8 Reassembling of running car part
2.2.2.4.4.8.1 Motor and motor gear box
Spread non-condensing glue on two surfaces of liner and screw threads of six bolts.
Assemble motor and motor gear box with six bolts, lift gear box as much as possible
before tightening bolts to ensure a maximum clearance between gear box and worm gear.
2.2.2.4.4.8.2 Stuffing box, bearing and bevel gear
Avoid enclosing bearing in inner side during bearing installation.
Spread non-condensing glue on two surfaces of gaskets to avoid leakage.
Ceruse should be plastered on M16 bolts during reassembling, lubricate stuffing box
and stuffing rope with running car oil.
2.2.2.4.4.8.3 Drive small gear, main shaft and spur gear
When main shaft goes through gear, keyway of shaft and gear should face upwards;
install closing ring after shaft goes through gear and move closing ring to keyway when shaft is in
right position.
Lubricate oil sealing and shaft with running car oil; oil sealing must not be damaged
during lubrication.
Put key into keyway to ensure closing ring in right position.
Install bearing closing ring on lifting ear, drive small gear and box cover, and make sure
that closing ring is at right position.
2.2.2.4.4.8.4 Worm
Check bearing, worm gear and oil sealing before assembling; if bearing pressing cover
is demounted for changing oil sealing, regulation gasket must be installed to ensure a proper
bearing clearance. During installation, the sharpened sides face to running car bottom. Lubricate
oil sealing lip and shaft.
Install motor and motor gear box parts.
Worm regulation
A. Tight bearing pressing cover with no gasket.
B. Measure gasket position and axial clearance.
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C. Put it gasket, its thickness should be 0.080.20mm bigger than axial clearance.
D. Measure axial clearance with micrometer.
2.2.2.4.4.8.5 Running car worm, spur gear and bearing box
Regulate small bearing axial movement to minimum value with gasket during
assembling, the gaskets decides right position of worm wheel to worm, spread bearing box bolts
with condensing glue or ceruse.
Worm-wheel shaft regulation

A. Install gear, worm wheel, bearing box and bearing onto shaft, screw down bearing lock
nuts and turn up gasket.
B. Press bearing to right position in bearing box, measures the depth from bearing outer ring
to bearing box process surface with micrometer, take values by stagger 180 and then take
average values.
C Measure the height of bearing upper cut with micrometer, take values by stagger 180 and
then take average values. The differential value of two average values is the thickness of
regulation gasket, gasket thickness is only 0.1mm, and thus worm wheel shaft axial movement is
within 0-0.1 mm.
Regulate gasket, sealing ring and bolts

A When regulating gasket and controlling tolerance as above, any sealing rubber can not be
used, light oil that can be extruded can be put if it necessary, gasket can be extruded to 0.1mm to
avoid oil leakage.
B Non-dry sealing gum should be plastered at two sides when compound gasket is only
used for sealing; besides, sealing gum should be plastered before installing oil sealing into hole.
C M8 bolts used at this part should be with torque of 30-40NM, generally used ring gasket
bolts should be screwed down on the cross.
Notes for worm wheel joggling regulation
A Observe and regulate through red lead powder plastered on teeth.
B Due to different kinds of reasons, joggling part of steel worm wheel and steel worm is very
important. Because all worm gear load on the same side, deflection method is adopted to improve
lubrication condition and ensure complete joggling of the teeth.
2.2.2.4.4.9 Lubrication
2.2.2.4.4.9.1 #450 gear oil is filled to running car gear box to midline position of oil pointer, #4 high
temperature grease is applied at stuffing box side.
2.2.2.4.4.9.2 Rack of gear should be lubricated with grease of molybdenum disulfide.
2.2.2.4.4.9.3 #4 high temperature grease should be filled to trolley bearing of front supporting
frame.
2.2.2.4.4.9.4 Lubricate oil also should be filled to screw thread phase tramformation actuator and
other nozzles.
2.2.2.4.4.10 Soot blower pressure regulation
2.2.2.4.4.10.1 Dismantle plug screw and connect pressure meter.
2.2.2.4.4.10.2 Start soot blower to get pressure readings.
2.2.2.4.4.10.3 Demount lock plug and regulate pressure regulation plate.
2.2.2.4.4.10.4 Install lock plug, restart soot blower to get readings.
2.2.3 TP500 temperature probe overhaul process, quality standard and notes
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2.2.3.1 If probe is needed to be suspended during major overhaul, four lifting ears on beam must
be used; chain, wire rope should be twined on beam for lifting to avoid damaging equipment and
causing faults.
2.2.3.2 Two screw thread pin installation holes should be on the same level during welding wall
tank, material of which is ZG30; angle between wall tank and connection sleeve (1336.5)
should be 900.5.
2.2.3.3 Welding rear end supporting ear plate: in cold state, supporting bearing should be at rear
section of ellipse groove, supporting and suspending ear plate should be welded at place
0.7~1.4m from beam rear end. Cables in beam should be protected to avoid burning.
2.2.3.4 Air cooling steam source parameter minimum flow is 0.02m3/s, minimum pressure is
20psig and maximum pressure is 200psig (1 psig=6894.76Pa).
2.2.3.5 After overhaul of cold state installation, probe rear end should deflect a certain distance in
horizontal surface and vertical direction according to boiler expansion at installation part to ensure
level of probe n hot state. No Drainage water pitch like soot blower exists.
2.2.3.6 Connection of power supply, control line on control box; connection on position converter
of position indicator at rear end of probe; compensation lead from temperature indicator to
thermocouple are connected on tap box of beam middle section. Compensation leads are different
while thermocouples are different. Note: polarity of position converter and compensation lead must
be right and shielded wire is needed. Polarity of connections of compensation lead and
thermocouple also must be right, specific connection arrangement diagram of probe is as
following:
2.2.3.7 Check whether straightness degree of beam has bending and distortion or not.
2.2.3.8 Check whether probe is damaged or not.
2.2.3.9 Check sealing of connection tube tie-in of cooling steam source.
2.2.3.10 Check whether all terminal connections of thermocouple is fixed or not.
2.2.3.11 Check whether all power and control line connection is fixed or not.
2.2.3.12 Check whether the position of shifting fork of journey switch is in right position or not.
2.2.3.13 Make sure that all cables, steel wire rope and cooling rubber pipe should be on their own
pulley and with at least 80mm droop but not under plane of beam bottom.
2.2.3.14 Rear end position and display cover plate must be opened before power-on trial operation
and after major overhaul of probe, take off steel safe between coiled wire wheel and coiled spring
according to requirement on warning plate on box; otherwise it will damage position conversion
actuator. Before demounting safety pin, check whether steel rope on big coil plate at back of box is
tightened or not; if it is not, loosen lock nut on coil plate and string steel rope and then screw down
lock nuts, then safety pin can be demounted. Whenever, safety pin must be reinstalled after
dismantling steel rope.
2.2.3.15 Power supply must be cut before manual operation for trial run. Ratched spanner can be
used to turn square handle at rear section of running car for manual operation, special
motor-driven spanner of IK soot blower also can be used. Manual operation is mainly to check
whether running car, pulley frame, probe gun operate normally or not, whether there is block or not,
whether cables, wires and rubber pipes are required to be regulated or not.
2.2.3.16 Power on trial run: operate manually and make sure that probe is at right position, all the
drive elements are normal, it can only be in power-on trial run after journey switch is at right
position. During trial run, push running car a certain distance and then send power on, check
whether all the electric connections are right or not. Regulate cooling system, temperature
measuring system and position converting system after it is confirmed that mechanical and electric
parts of drive system are normal.
2.2.3.17 Running gear box uses #30 machinery oil. According to using condition, lubricate oil
should be changed once about one year, lubricate oil should be filled once per year. During motor
73
lubrication, end cover should be dismantled and excellent high speed bearing grease should be
filled.
2.2.3.18 Dismantling and installing of running car see as IK500 series soot blower.
Part Two Boiler Auxiliary Equipment Maintenance
Chapter Coal Mill Maintenance
1 Applicable Scope and Quoted Material

This chapter is applicable for HP1163 type grinding roll mill produced by Shanghai Heavy
Machinery Company Limited for, to offer basic maintenance and overhaul bases for guiding coal
mill maintenance personnel.
Quoted material:
HP1163 Type Coal Mill Technical Drawings and Material Combined version Shanghai
Heavy Machinery Co., Ltd.
HP1163 Type Coal Mill Operation Manual Shanghai Heavy Machinery Co., Ltd.
HP1163 Type Coal Mill Hydraulic Pressure System Material Brought with the Mill
DL/T748.4 Thermal Power Plant Boiler Overhaul Guide Rules Part Four Pulverizing
System Overhaul
Twenty five Key Requirements on Prevention of Major Accidents Requirements in Electric
Power Generation
2 Equipment Brief Introduction and Parameters
2.1 Brief Introduction
The pulverizing system Indonesia Paiton 1660MW coal fired thermal power plant adopts
middle speed mill cold primary air, which is positive pressure, direct blowing pulverizing system.
Six (6) HP1163 middle speed mills produced by Shanghai Heavy Machinery Company Limited are
equipped for each boiler; five (5) mills are in operation and one (1) in standby under the condition
of burning design coal, each mill is for one layer burners of the boiler. HP1163 type coal ill is a
grinding roll coal mill, grinding part of which consists of rotational grinding rings and three fixing
grinding rolls that roll along grinding roll and be able to turn by it. Raw coal drops onto grinding roll
from coal chute in the middle of coal mill, which moves raw coal to grinding rolling tunnel under
force of gravity; and raw coal is grinded and milled by grinding roll. The three grinding rolls are
evenly distributed on millstones along circumference; grinding force is produced by spring loading
system and effect evenly on grinding rolls through three-point system, this force is transmitted to
foundation through grinding ring, grinding roll, press frame, lever, drive plate, reducer, hydraulic
pressure cylinder and then soleplate. Grinding and drying are processed at the same time, primary
air enters into circumference of grinding roll through spray nozzles and sends coal powder thrown
out in tangential direction from grinding ring to separator at upper section of mill. Coal is separated
in separator, coarse powder is separated and returned to grind ring for grinding and qualified
powder is brought out of separator by primary air.
Carpolite coal, pyrite and iron block that are difficult to crush and can not be blown up enter
into primary air box through spray nozzle ring and then blowed into slag removing box and cleaned
by workers periodically.
HP1163 type mill adopts squirrel-cage asynchronous motor for driving and transfer torque
through star gear reducer. Reducer can bear upper section weight and vertical load caused by
force of grinding loading.
Lubrication oil station equipped with reducer is for fostering and cooling gear oil in reducer to
ensure all parts in reducer are in fine lubrication state.
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Totally six (6) mill and two sealing air fans are equipped for one boiler, sealing air fan is used
for sealing at places of mill drive plate, lever joint bearing and grinding roll.
Connect a turn gear device at tail section of motor when repairing coal mill.
2.2 Equipment specification and parameters
2.2.1 Pulverizing System Type: Middle speed mill with cold primary air fan positive pressure
direct blow pulverizing system
2.2.2 Configured Sets: Six (6) middle speed coal mills are equipped for each boiler; for design
coal, output (10% output decreasing is considered) of five (5) coal mills should be no less than
110% of coal consumption under B-MCR working condition of the boiler, and the rest one is in
standby; for checked coal, total output of five coal mills in operation should meet 100%
requirement under B-MCR working condition of the boiler.
2.2.3 Installation Location: boiler house zero meters
2.2.4 Coal Powder Particle Size: R90=22%
Coal powder moisture: Design coal: 18%
Checked coal: 18.9%
2.2.5 Coal Feeder:
2.2.5.1 Type: Electronic measuring coal feeder
2.2.5.2 Quantity: One for each coal mill and six for each boiler
2.2.5.3 Maximum continuous coal feeding amount: 110 t/h10% coal feeding abundance is
considered
2.2.5.4 Measuring precision: 0.5 %

2.2.5.5 Control precision: 1%
2.2.6 Fire fighting and Inverting Steam Source Parameters:
2.2.6.1 Fire fighting and inverting steam pressure: 0.40.6 MPa
2.2.6.2 Fire fighting and inverting steam temperature: 170

2.2.7 Cooling water
2.2.7.1 Cooling water system type: closed cooling water system
2.2.7.2 Cooling water working temperature: maximum 38;
2.2.7.3 Cooling water working pressure: 0.3MPa
2.2.7.4 Cooing water amount: 20m/H

2.2.8 Cool mill type: HP1163 bowl type middle speed mill
2.2.8.1 Separator type: Static centrifugal baffle separator
2.2.8.2 Grinding roll loading type: loading with spring changing
2.2.8.3 Foundation type: fixed foundation
2.2.9 Single Mill Output
2.2.9.1 Particle of coal entering into mill: 0~35mm (95%), 35~50mm(5%);
2.2.9.2 Maximum output (110% load of mill): 89.64 t/h;
2.2.9.3 Calculated output (BMCR): 62.56 t/h;
75
2.2.9.4 Minimum output: 24.9 t/h
2.2.9.5 Regulable range of particle size of coal powder: R90 =10%40%

2.2.10 Coal Mill Ventilation
2.2.10.1 Maximum ventilation (110% load of mill) : 149.31 T/H;
2.2.10.2 Calculated ventilation: (BMCR)
Design coal: 143.7 T/H
Checked coal: 142.3 T/H
2.2.10.3 Minimum ventilation: 19.12 kg/s;
Design coal: 143.3 T/H
Checked coal: 143.3 T/H
2.2.10.4 Recommended temperature of dry air at inlet of mill: design coal: ~274
Checked coal: ~304
2.2.10.5 Dry medium temperature at outlet of coal mill: design coal: 65
Checked coal: 65;

2.2.10.6 Bearing power of mill under condition of ensured output: 644 kW;
2.2.10.7 Mill running speed: 27.7 r/min

2.2.11 Mill resistance (including separator, coal powder distribution box)
2.2.11.1 Mill maximum ventilation resistance: 4500Pa
2.2.11.2 Mill ventilation resistance (100% load of mill)
Design coal: 4147Pa
Checked coal: 4147Pa
2.2.11.2 Mill calculated ventilation resistance (BMCR):
Design coal: 3663Pa
Checked coal: 4086Pa
2.2.12 Life
2.2.12.1 Grinding roll (single face) 25000h
2.2.12.2 Grinding bowl lining plate 25000h
2.2.12.3 Air ring nozzle (moving and stationary air ring) 20000h
2.2.12.4 Sealing piece ensured life 22000 h
2.2.12.5 Coal powder separator life 25000 h
Material high chromium cast iron
2.2.12.6 Carpolite coal scraper life 10000 h
Material high chromium cast iron
2.2.13 Mill Sealing Air
2.2.13.1 Total sealing air amount of mill: 98.22 m/h
2.2.13.2 Differential value of sealing air of mill and primary air pressure: 2000 Pa
76
2.2.13.3 Mill abrasion rate per unit (under condition of ensuring output):
Design coal: 1.953g/t
Checked coa l: 1.885 g/t
2.2.13.4 Mill power consumption per unit (under condition of ensuring output):
Design coal: 9.2 kWh/t coal
Checked coal: 9.8 kWh/t coal
2.2.14 Drive Device
2.2.14.1 Reducer type: KMP360
2.2.14.2 Drive type: spiral bevel gear + star gear two-stage vertical drive
2.2.14.3 Transmission ratio: 35.6
2.2.14.4 Oil volume: 850 L
2.2.14.5 Gear box external dimension: 194019401700
2.2.14.6 Gear box weight: 17 T
2.2.14.7 Oil pump quantity: 1 set /set mill
2.2.14.8 Oil pump flow: 287 L/min
2.2.14.9 Oil pump motor power: 15 kW
2.2.14.10 Norma oil supplying pressure: 0.15-0.35 MPa
2.2.14.11 Oil cooler quantity: 1 set/set mill
2.2.14.12 Oil cooler cooling water flow: 20 m3/h
2.2.14.13 Oil cooler cooling water pressure: 0.3 M Pa
2.2.14.14 Oil cooler cooling water temperature: 38

2.2.14.15 Oil tank electric heater quantity: 1 set/set
2.2.14.16 Oil tank electric heater rated voltage: 220 V
2.2.14.17 Oil tank electric heater rated power: 35.5 kW
2.2.14.18 Lubricating oil trademark: ISOVG320
2.2.15 Main Motor
2.2.15.1 Type: YHP630-6
2.2.15.2 Rated power: 850 kW
2.2.15.3 Rated rotating speed: 982 r/min
2.2.15.4 Rated voltage: 6 kV
2.2.15.5 Moment of inertia: 100 kgm2
2.2.15.6 Power standby coefficient: 1.15
2.2.15.7 Cooling type: IC611 (air - air cooling)
2.2.15.8 Weight: 9000 kg
2.2.16 Sealing Air Fan
2.2.16.1 Type 9-26,16D-4
2.2.16.2 Quantity 2 set/boiler
2.2.16.3 Rated air amount 64032 m3/Ht =35
77
2.2.16.4 Rated lifting pressure head: 6481kPa
2.2.16.5 Motor rated power: 185 kW
2.2.16.6 Motor rated rotating speed: 960 r/min
2.2.16.7 Motor rated voltage: 380 V
2.2.16.8 Motor weight: 9320 kg
2.2.17 Air Filter
2.2.17.1 Type: 60M
2.2.17.2 Quantity: 2 set/boiler
2.2.17.3 Room quantity in single room: 16 rooms
2.2.17.4 Air capacity in single room: 70.75 m3/min
2.2.17.5 Resistance: 1370Pa
2.2.18 Interface Dimension:
2.2.18.1 Primary air inlet dimension: 2667813 mm (inner wall), wall thickness: 10mm
2.2.18.2 Center coal chute dimension: 660 mm (outer diameter), wall thickness: 10mm
2.2.18.3 Coal powder interface dimension: 6762mm (outer diameter), wall thickness: 10mm
2.2.19 Carpolite Coal Discharge Outlet Flange
2.2.19.1 Carpolite discharge outlet flange outlet nominal height: 2.193 m (mill center line)
2.2.19.2 Carpolite discharge outlet flange outlet inner diameter: 350 mm; outer diameter:
395 mm
2.2.20 Maximum Part Lifting Weight during Installation of Mill: 28000KG (reducer)
2.2.21 Maximum Part Lifting Weight during Maintenance of Mill: 35000KG (separator)
2.2.22 Required Maximum Height during Maintenance of Mill: 10.4 m
2.2.23 Separator Outer Diameter: 5.410 m
2.2.24 Explosion-proof Steam Parameter:
2.2.24.1 Explosion-proof steam pressure: 0.40.6 MPa
2.2.24.2 Explosion-proof steam temperature: 180

2.2.25 Mill Main Parts List and Total Weight
No. Part Name Quantity (set/set) Weightkg Remark
Discharge valve and

1
multi-outlet device
1 6000four outlets
2 Separator coping device 1 26807

3 Inner cone device 1 2088
4 Separator device 3 35000
5 Differential pressure system 1 13
6 Mill bowl and impeller device 1 33000
Side body and its lining plate
7 1 32400
device
78
8 Scraper device 1 171
9 Star gear reducer box 1 28000
Seam air sealing and
10 1 540
protection cover device
11 Air sealing system 1 1300
12 Grinding roll device 3 15137
13 Spring loading device 3 5400
14 Inverse cone device 1 96
15 Outlet air sealing system 1 210
16 Motor 1 9320
17 Coupling 1 469
18 Coupling protection cover 1 119
2.2.26 Special Tools
Producing
No. Name Specification Unit Quantity Manufacturer Remark
area
Grinding roll turning
1
out device
Mill bowl lifting
2
device
Roll dismantling
3
device
Reducer moving
4
device
Reducer and side
5
body align device
HP1163 set 1 Shanghai Shanghai
Spring
6 pre-tensioning
device
Pre-tensioning
device of connection
7
bolts of mill roll and
reducer
Oil level amount oil
8
lever
9 Sampling device
2.2.27 Imported Pieces List
No. Name Specification Unit Qty Producing
Manufacturer Remark
area
1 Reducer HP1163 special Set 6 Germany FAG/SKF
Grinding roll
2 GP-6639 Piece 36 Japan NSK
bearing
3 Grinding oil GP-6640 Piece 54 Taiwan H&H
sealing
79
4 Loading spring GP-3271-S Piece 18 America ALSTOM
5 Soot blower MP8973 Piece 18 America ALSTOM

For
Air pressure differential
6 MP8974 Piece 1 America ITT
regulator pressure
control
Pressure Piece
7 MP10278 6 America ALSTOM system
switch
8 Lubricating oil station
Lubricating oil
8.1 OWTS11 set 6 Hongkong PARKER
station
Pressure
differential BH-001001-001 Piece 6 America SOR
switch
Pressure
BH-001003-001 Piece 12 America SOR
switch
8.2
Temperature
switch
Flow switch MN-DSF320LM Piece 6 America UFM
Liquid level
switch
For
Material level
9 UFI7P00 Piece 6 Germany UFI carpolite
switch
coal
3/4 inch Piece 6 Coal
powder
Solenoid valve pneumatic
10 with double Japan SMC quick
rings 3/8 inch Piece 6 close
valve
11VDC
Grinding roll
piling welding
11 HP1163 special KG 12384 Germany VAUTID
rod and
solution
2.2.28 Related Drawings
2.2.31.1 HP1163 Type Coal Mill Technical Drawings and Material Combined version
Shanghai Heavy Machinery Co., Ltd.
2.2.31.2 HP1163 Type Coal Mill Operation Manual Shanghai Heavy Machinery Co., Ltd.
3 Maintenance Items, Sort, Cycle and Period

3.1 Major Overhaul Items
Cycle: 2 years
No. Items
1 Grinding roll tyre check, replace and turning over
80
2 Clean and changing oil for grinding roll oil room
3 Check and replace moving and stationary ring abrasion
4 Measure and replace grinding plate lining tile abrasion
5 Check and replace carbon-type seal
6 Check and replace anti-abrasion guard plate
7 Check and replace slag removing scraper
8 Check and mend separator abrasion
9 Check and fix coal chute supporter
10 Check and replace outlet turning baffle of separator
11 Check and replace sealing air pipe (grinding roll)
12 Dismantle and check spring loading device
13 Countercheck grinding roll center
14 Check and replace grinding roll bearing
15 Clean, check and change oil for inner part of reducer
16 Check and replace thrust pad of reducer
17 Clean, check, repair and change oil for lubricating oil system
18 Check and repair hydraulic loading system
19 Check and repair fire fighting steam system
20 Others
3.2 Minor Overhaul Items
Cycle: 6 years
No. Items
1 Measure thickness and check roll sleeve abrasion
2 Change oil for grinding roll
3 Measure thickness and check lining tile abrasion
4 Check and regulate guide clearance
5 Check and mend anti-abrasion guard plate
6 Check and replace slag removing scraper
7 Clean, check and replace sieve of lubricating oil system
8 Check and repair fire fighting steam system
9 Dismantle and check spring loading device
10 Install anchor bolts and jacking bolts
11 Others
4 Maintenance Process, Process Method and Quality Standard

4.1 Separator Maintenance Process, Process Method and Quality Standard
4.1.1 Stop lubricating oil system, all inlets and outlet pipeline of coal, air, powder and steam should
be reliably isolated.
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4.1.2 Dismantle the connection bolts of first flange of separator and coal chute & coal powder pipe.
4.1.3 Dismantle sealing air elbow connecting to separator.
4.1.4 Dismantle connection bolts of flange of separator and shell.
4.1.5 Dismantle loop air pipe at upper section of separator and sealing air short pipe connecting
with grinding roll.
4.1.6 Dismantle flanges of fire fighting steam pipeline on shell. Install block plate on flange of
steam inlet pipeline to avoid impurities. Inform I & C personnel to dismantle all I & C detection
points.
4.1.7 Dismantle guardrails influencing suspending separator and put it onto designated location.
4.1.8 Suspend separator with one-track crane for 100mm and put it onto separator maintenance
platform.
4.1.9 Open all manhole valves of separator and confirm that there is no gas in separator. Clean
accumulated powder and impurities in separator.
4.1.10 Check abrasion carefully at parts of cone, supporting plate, outlet branch pipe and coal
feeding pipe of separator with thickness gauge; take records well. It should be mended if part
abrasion exceeds more than 2/3 of original thickness; it should be changed if abrasion of more
than 60% area exceeds 2/3.
4.1.11 Check abrasion of regulation damper with calipers and take records well. Regulation
damper with abrasion exceeds 2/3 of original thickness should be changed.
4.1.12 Check and repair drive actuator of regulation damper, drive actuator should turn freely and
be free from block; regulation damper openness is consistent.
4.1.13 Check abrasion of return valve and take records well. Return valve switch should be agile
and free from block. It should be changed when abrasion of return valve exceeds 2/3 of original
thickness.
4.1.14 Change all sealing stuffing of flange joint faces on separator, manhole and check valve,
make sure that all the joint faces are strict and free from leakage.
4.1.15 Molybdenum disulfide should be plastered on all bolts and nuts to avoid blocking due to
high temperature.
4.1.16 Check all the welding lines in separator whether are smooth or not and free from
accumulated powder or not.
4.1.17 Reinstall separator in reversal sequences from 1.5.1.1 to 25.1.9.
4.1.18 Reinstalling quality standard of separator
4.1.19 Regulation damper openness should be consistent with actual condition; clearance of
40mm should be preserved when closing it.
4.1.20 All stuffing used between joint face of all holes and flanges should be used according to
design requirements of manufacturer, sealing stuffing should be put at right position during
reassembling, keep all the joint faces strict and free from leakage.
4.1.21 Liner such as flange is not allowed not extend into inside of separator or other pipelines to
avoid added resistance due to accumulated powder.
4.2 Process, Process Method and Quality Standard of Maintenance Process, Dismantling
and Installing for Spring Device
Dismantling of Spring Device
4.2.1 Dismantle sealing air pipeline from spring device, loosen nuts of bolts on limit lever of
grinding roll.
4.2 1 Clean pre-pressing force of spring with hydraulic loading device
4.2.1.1 Check that minimum clearance between grinding roll head filler block and spring
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eject-plate is 1.5mm, lowing down grinding roll can be adopted to ensure the clearance.
4.2.1.2 Loosen four (4) hexagon nuts at outer side.
4.2.1.3 Use four hexagon nuts at inner side to retreat spring seat a distance from mill cover, the
distance is pre-compression adding with 1215mm, that is 45.848.8mm.
4.2.1.4 Screw in the four outside thick nuts manually to press spring seat.
4.2.1.5 Install spring pretension tool as per drawings of KF3868.2.0.
4.2.1.6 Pump oil into oil cylinder as per list P in drawings of KF3868.2.0.
4.2.1.7 Dismantle key on spring plunger, retreat lock nuts as per pre-compression of spring.
4.2.1.8 Release pressure of oil pump slowly, lock nut should be at lax state; otherwise release
pressure until lock nuts are in complete laxation.
4.2.1.9 Dismantle spring pre-compression tool.
4.2 1.10 Dismantle outside connection bolts.
4.2 1.11 Dismantle spring seat from mill cover by lifting it with lifting holes on spring seat flange,
dismantle bolts of lever.
4.2.1.12 The end with spring should face down and put spring device vertically, dismantle sealing
air cover and ventilation orifice plate. Check whether it has abrasion or not, replace it if abrasion
exceeds 3mm.
4.2 .1.13 Lay spring devices in turning over position (fill up square box or pad at inner side of
spring seat flange). Dismantle bolts on spring seat cover; lift spring plunger, spring seat cover and
spring lock nut out as a whole from spring seat, clean the inside of spring seat.
4.2 1.14 Demount lock nut, spring seat cover, spring mattress and spring in sequence.
Reassembling of Spring Device
Before reassembling, clean all inner parts of spring seat and spread paint on non-processing
surfaces.
Note: paint will not be plastered on cooperation surface, screw thread end and bearing surface.
4.2 1.15 Make inner side surface of spring seat flange face up and spring seat upright. Install
bushing in cold state in spring seat, the shaft end surface with screw should face up and then
install closing rings.
4.2 1.16 Turn over spring seat 180, make it stand up and block up it 125130mm from ground.
4.2 1.17 Install another bushing in cold state in spring seat cover.
4.2 1.18 Install spring plunger; spring mattress, spring, spring seat cover and spring lock nut as a
whole; install a lifting eye bolt at one end of spring plunger, install it into spring seat. It should be
paid attention when spring plunger goes through bushing to avoid damaging bushing.
4.2 1.19 Install bolts of spring seat cover and screw down as per B-GP-2175. Install grinding roll
limit lever bolts and nuts.
4.2 1.20 Lay down spring seat or turn it over in stand, install spring ventilation air orifice plate and
sealing air cover. Screw down inner hexagon bolts as per B-GP-2175.
4.2 1.21 Install spring devices onto mill cover.
4.2 1.22 Set pre-compression of the spring (see as preloading method of spring device in 3.12.1).
This work can be done before installing mill cover onto mill and also can be done together with
installing mill cover; of course the former is more convenient.
4.2 1.23 Regulate clearance between grinding roll sleeve and grinding roll lining plate.
4.2 1.24 Regulate clearance between spring device and grind roll head.
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4.2 1.25 Install sealing air pipeline.
4.3 Grinding Roll Maintenance Process, Process Methods and Quality Standard
4.3.1 Move away separator, dismantle pressing frame and lift it out, and then dismantle sealing air
vertical pipeline of grinding roll. Install special lifting tools of grinding roll. Lift any grinding roll with
crane slowly and loosen fixing bracket of the grinding roll and then lift the grinding roll to
designated location. Lift the other two grinding rolls to designated location with the same method
above (Oil in grinding roll should be discharged when mill grinding roll is in hot state).
4.3.2 Lay down grinding roll in level with crane and make end cover face upwards, loosen roll tyre
pressing ring bolts, take off spring gasket of bolt and safety piece and put them to designated
location. Take off pressing ring with compression bolts and put it at designated location, screw
stem of drawing roll tyre device into screw threads of transportation sleeve.
4.3.3 Regulate hanger and jack fixing drawing roll tyre device, draw out roll tyre stably with jack
and draw it out after even heating up if it is necessary. During heating, the distance between flame
spraying nozzle and roll tyre surface should be 100150mm, and heat up the outside circle of roll
tyre evenly to about 65, direct welding for heating up roll tyre is prohibited, because it may result
in crack or rejection to roll tyre.
4.3.4 After drawing out roll tyre and then turn over grinding roll with 65 with crane to make support
frame of grinding roll face up.
4.3.5 Loosen pressing plate bolts of shaft head, take off pressing plate bolts and lining plate and
put them at designated location.
4.3.6 Dismantle filling bolts outside roll frame and screw bolts of roll frame drawing device into
these screw threads, install roll frame drawing device and jack and regulate it well.
4.3.7 Draw out roll frame with jack stably, draw out roll frame with heating up method if it is
necessary. See as in following:
English
Jack plate
Bolt
30T 30T hydraulic jack
Pressing cover
4.3.8 Loosen hexagon bolts of transparent cover; take off bolts, gasket and safety piece and put it
into designated location.
4.3.9 Loosen and take off filling bolts and gasket of transparent cover, screw compression bolt into
screw threads and take off transparent cover to put it at designated location by the compression
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bolt.
4.3.10 Take out sealing ring, oil sealing, oil sealing pressure bearing ring and shaft sleeve and put
at designated location.
4.3.11 Loosen hexagon bolts of inner sleeve pressing ring of roller bearing; take off pressing ring,
bolts, gasket and safety piece and put them at designated location.
4.3.12 Turn over grinding roll carefully with crane, which is shaft head faces down, and put it on
special platform.
4.3.13 Loosen bolts of fixing end cover take off bolts, gasket and safety pieces and put them at
designated location.
4.3.14 Screw compression bolts into filling screw threads of end cover, take off O type ring
together with end cover and put them at designated location.
4.3.15 Loosen pressing plate bolts of shaft end at end cover side take off bolts, gasket and safety
pieces and put them at designated location.
4.3.16 Install special bolt stem of jacking shaft head, fixing frame and jack on roll shell, take out roll
shaft together with roller bearing inner bushing and put them at designated
location.
English
Screw stem
30T Splitter hydraulic jack
M30 M30 nut
Jack plate
M16 M16 bolt of flying rings
4.3.17 Take out swinging bearing with special device for tightening, heating up method can be
adopted if it is necessary. See as in following:
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English
M30 M30 nut of screw stem
Supporting stem
Jack plate
30T Splitter hydraulic jack 30T
Flying ring bolt
Pressing plate
4.3.18 Turn over roller hub together with column bearing sleeve carefully with crane and put them
well. Take out column bearing sleeve together with rolling column with special device for tightening,
heating up method can be adopted if it is necessary. See as in following:
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English
Screw stem
Supporting stem
M30 M30 nut
Jack plate
M16 M16 bolt of flying rings
Demounting tools
4.3.19 Take off column bearing inner sleeve from bearing with special drawing device for
tightening, see as in following:
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English
M30 M30 nut of screw stem
Jack plate
Bolt of flying rings
Pressing cover
Pulling ring
4.3.20 Clean and check dismantled parts from grinding roll and take technical records, confirm
whether these parts can be used continuously or not.
4.3.21 Grinding roll bearing should be free from blow spot, crackle and so on. It should comply
with national standard and manufactures standards. Bearing sleeve should be free from injury,
trace and rust. Its rotary surface should be glabrous; round degree, concentricity and cone degree
on radial diameter should be within permit error range. Oil sealing should be complete and free
from damage, meeting using requirements.
4.3.22 Put roller bearing inner sleeve into oil and heat it up to and then assemble
with grinding roll (heating up time should be no less than 15 minutes), and then put it onto special
maintenance platform for cooling.
4.3.23 Reinstall roller bearing inner sleeve, tighten it with bolts. Bearing inner sleeve abuts against
bearing shoulder, the clearance between pressing ring and bearing shoulder is 0.71.30mm.
4.3.24 Lift roller shell onto special bracket and heat it up with swinging bearing side facing upward.
Install swinging bearing into roller shell.
4.3.25 Turn roller shell and install roller bearing outer sleeve into hot roller shell together with
rolling column. And then install roller bearing into shell vertically together with roller bearing inner
sleeve.
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4.3.26 Cover and press roller shell and bearing with special cover, cool it down naturally and then
check the agility of bearing.
4.3.27 Measure clearance with feeler gauge or pressing lead method. Error of bearing NU3192
and 24156B after assembling is 220-330m and 190-280m respectively.
4.3.28 Pressure oil bolts threads and holes at rolling bearing side should be filled with bolts
plastered with sealing agent for tightening and sealing.
4.3.29 Heat up bearing sleeve to 8090 and then assemble it with roller bearing; after it is
cooled down, install gland sealing O type ring plastered with grease between roller bearing and
bearing sleeve.
4.3.30 Install special O type ring plastered with grease into roller shell, reinstall transparent cover
and tighten it on roller shell. Check anti-abrasion ring, O type ring should be free from aging or
damaging. Clearance between transparent cover and roller bearing outer sleeve should be 0
0.40mm and clearance between transparent cover and inner sleeve pressing ring should be
3+0.60mm.
4.3.31 Install oil sealing and oil sealing pressure bearing ring between bearing sleeve and
transparent cover with special pressing ring. Oil sealing should be complete and free from damage,
installation direction should be right. During installing by pressing, grease should be filled into oil
sealing, oil sealing and oil sealing supporting ring should not be damaged.
4.3.32 Take off special tools and then measure and regulate sealing ring clearance, install oil
sealing closing ring and then tighten it.
4.3.33 Turn roller shell with crane and keep swinging bearing side facing upwards. Install stop ring
for bearing and reinstall pressing plate of bearing head, tighten and insure it.
4.3.34 Tighten pressure oil thread screw hole at swinging bearing side with filling bolts plastered
sealing glue.
4.3.35 Install special O type ring plastered with grease into end cover slot, reinstall end cover;
mixture of ceruse and machinery oil should be plastered onto connection bolts.
4.3.36 Block all leaking points and do the air tightness test to roller cavity with clean and dry
compressed air; roller cavity should be strict and free from leakage, test pressure is 0.2Mpa with
30min of pressure keeping time. Qualified standard pressure drop is under 0.1Mpa and test
pressure should not exceed 0.3Mpa.
4.3.37 After test is qualified; check viscidity of lubricating oil, measure neutral value and cleanness,
fill in qualified lubricating oil and antiseptic.
4.3.38 Measure and check abrasion of roller tyre under help of sampling plate, roller tyre can be
continuously to be used after turning over 180 when its surface abrasion is 2/3, it should be
replaced if residual thickness is 15mm and corresponding lining tile must be renewed. It should be
replaced if roller tyre has crackles.
4.3.39 Lift special roller tyre device with special lifting tool and heat up roller tyre to 5060
evenly and slowly. Drop them slowly after aligning roller tyre and roller shell in level. During
heating up, fire can not be used directly to heat up roller tyre quickly; too fast heating may result in
cataclasm of roller tyre.
4.3.40 Dismantle special tools and reinstall roller tyre pressing ring.
4.3.41 Check anti-abrasion ring, it should be renewed if abrasion exceed 2/3, reinstall qualified
anti-abrasion ring.
4.3.42 Check abrasion condition of grinding roll and take records well, roller frame abrasion should
not exceed 1/2 of original thickness.
4.3.43 Check and measure radial clearance between air ring and transparent cover, the clearance
value is 0.400.78mm, fix qualified air ring with bolts plastered with molybdenum disulfide.
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4.3.44 Loosen filling bolts in transportation screw thread holes at outside of roller frame, screw in
suspending ring and lift roller frame onto special supporting frame.
4.3.45 Check cooperation of roller frame bearing aperture and bearing neck, heat up roller frame
to about 65 evenly and lift it onto roller bearing with crane, drop it down slowly after alignment
until roller frame contacts with bearing sleeve.
4.3.46 Tighten bearing plate with bolts plastered with molybdenum disulfide, loosen suspending
ring and screw in filling bolts.
4.3.47 Clean air filter and purge it with compressed air, and then reinstall it.
4.3.48 Check joint face of bearing cover and roller frame, joint surface should be smooth, put
sealing gasket in-between and reinstall bearing cover.
4.3.49 Check self-corrosion frame behind roller frame, it should be changed if abrasion exceed 2/3
of original thickness. Check rolling column groove of roller frame and rolling column that should be
smooth and free from crackle.
4.3.50 It should be replaced if abrasion of sealing air swinging pipe of grinding roll exceed 2/3 of
original thickness, it should be replaced if abrasion of inner copper sleeve of short connection pipe
of sealing air exceed 2/3.
4.3.51 After assembling of grinding roll, agility test should be done for the grinding roll and its
turning should be agile and free from block.
4.3.52 All tightening bolts should be evenly tightened during grinding roll reinstalling, gasket and
safety pieces should be complete and fine, bolts should be plastered with molybdenum disulfide.
After reinstalling roller frame, if grinding roll is needed to lift, lift ring of filling screw thread at
outside of roller frame should not be used, because the grinding roll is very heavy.
4.3.53 Lift repaired grinding roll into mill with over trace crane, fix it with fixing frame of grinding roll,
and align the grinding roll with special tools. Align grinding roll with 15 aligning lever, its concentric
degree should not exceed 3mm.
4.4 Millstone and Tile Lining Maintenance Process, Process Method and Quality Standard
4.4.1 Measure the clearance between nozzle ring and stationary ring and take records. See as in
following:
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4.4.2 After lifting grinding roll and all parts at upper section inside mill, dismantle upper cover of mill
plate and put them at designated location by using crane. Lift mill plate and nozzle ring
subassemblies by using three lifting ears and three steel ropes with same length and put them at
designated location.
4.4.3 After dismantling and lifting all parts of grinding roll and upper section of mill, dismantle upper
cover of mill plate and lift them with crane and put them at designated location.
4.4.4 Turn mill plate 180 by using crane and make joint face of mill plate and drive plate face up.
Dismantle wedge bolts of lining tile and then demount bolts, sleeve and disc spring. Demount bolts
on two jacking bolts at lower section of tray for preparation of dismantling first lining plate.
4.4.5 Turn mill plate 180 by using crane and make lining tile face up. Screw corresponding jacking
bolts into screw to jack first lining plate; if it can not be jacked up, accumulated coal in gap of lining
tiles apertures (it is better to immerse lining tile in water to loosen accumulated coal for
convenience of cleaning coal), and then jack it.
4.4.6 Lift the first lining plate by special tool of grinding ring lining plate. Lining tile should be taken
and put down slowly, no bumping or metal collision is allowed, any heating to lining plate is not
allowed neither.
4.4.7 Loosen all the rest lining plate and lift them in sequence; clean and check mill plate and
check whether there is damage and crackle or not.
4.4.8 Check abrasion of dismantled lining tile by using sampling plate. Abrasion should not exceed
60% of original thickness generally and it should be replaced when residual thickness is 10mm.
Lining tile should be replaced after roller tyre turning over.
4.4.9 Clean tightening bolts and screw threads apertures.
4.4.10 Check new lining tile completely. Check the thickness of every lining plate with benchmark
of lowest point of R393 arc surface and mark it.
4.4.11 Lift lining tile into mill plate with crane. A90 column pin should be installed on lining plate
roller ring before installation of the first lining; the rest should be assembled as per sequence
numbers. The twelve (12) lining plates must be with sequence number and serial number
sequences should be decided according to their height. Its principle is to make differential height of
two neighboring lining tiles be at minimum. Installation requirements of the twelve (12) lining plates
in mill ring are as following:
The thickness from the thickest to the thinnest is: H1, H2, H3, H4, H5, H6, H7, H8, H9, H10,
H11 and H12 (that is their thickness is H1H2H3H4H5H6H7H8H9H10H11H12).
Installation number is 1, 2, 3, 4, 5, 6, 7, 8, 9, 10, 11 and 12 in clockwise.
Corresponding relation between installation number and thickness H is as following:
No. 1 2 3 4 5 6 7 8 9 10 11 12 Clockwise
Thickness H1 H2 H3 H4 H5 H6 H7 H8 H9 H10 H11 H12
H1H2H3H4H5H6H7H8H9H10H11H12
4.4.12 during installation of every lining plate, clearance between lining plate undersize and mill
ring tray plate should not exceed 0.1mm.
4.4.13 after installation of every lining tile, the clearance between it and previous tile should not
exceed 1mm.
4.4.14 after lining plate is positioned; check the differential height at lowest point of R393 arc
surface of every two neighboring lining plates one by one. The value should not exceed 2mm.
After installation of lining tile, check the clearance of lining tiles, gasket can be filled in if clearance
is too big.
4.4.15 Hammer compression bolts head when installing cuniform bolts, assembling of nuts, sleeve
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and disc spring should comply with drawings.
4.5 Drive Plate Maintenance Process, Process Method and Quality Standard
4.5.1 Measure the clearance between drive plate and shell sealing and take records.
4.5.2 Dismantle connection bolts of drive plate and output flange of reducer with special tools and
put them at designated location. Demount sealing air pipeline leading to sealing cavity of shell.
4.5.3 Prepare brackets for jacking four (4) drive plate, four (4) 30T jack and four (4) overpressure
manual pumps.
4.5.4 Start turning gear to stagger scraper plate of drive plate and four flange holes. Install the four
(4) brackets for jacking drive plate.
4.5.5 Put four (4) jacks on bracket; install fixing plate, fixing jack and bracket of stop pad. Connect
manual pump for jacking pressure, jack drive plate evenly and synchronously to position that is
30-50mm higher than outlet flange top of reducer. Pull on fixing pin into jacking device and install
safety pin.
4.5.6 Check whether shell sealing ring and carbon-type sealing ring is in distortion or not. It should
be replaced if it exceeds standard.
4.5.7 Check abrasion of scraper.
4.5.8 Reinstalling is done in reversal sequence from 1.5.5.1 to 1.5.5.7.
4.5.9 Install carbon-style sealing ring and carbon sealing well during reinstalling. Fix it with
adhesive tape, dismantle them after installation of drive plate.
4.5.10 Install three positioning levers of drive plate. Lift and install drive plate, connection bolts and
thrust plate. Reinstall scraper and regulate clearance, the clearance between scraper and upper
end surface of shell should be 82.0mm.
4.6 Sleeve Maintenance Process, Process Method and Quality Standard
4.6.1 Guard plate should be replaced if its abrasion thickness is bigger than 2/3.
4.6.2 Cut guard plate of sleeve.
4.6.3 After installing new guard plate, connection seam should be strict, its surface should smooth
and free from obvious concave and protruding. Welding should be in fastness.
4.7 Lubricate Oil Station Maintenance Process, Process Method and Quality Standard
4.7.1 Check leaking points on oil pipeline of lubricating oil station, clean the leaking point.
4.7.2 Check oil pump at oil station, replace damaged parts.
4.7.3 Replace filter, filtrate and analyze lubricating oil. It should be replaced if it is not qualified.
4.7.4 There should be no leaking points after trial run and maintenance of oil station. Output
should meet using requirements.
4.7.5 Paint the equipment of oil station.
4.8 Reducer Maintenance Process, Process Method and Quality Standard
4.8.1 Tools to be prepared: four jacks, lever hoist, jack chain and some20-40600 round steel.
4.8.2 Mark all the positions of reducer for the convenience of reinstalling. Dismantle outside
accessorial pipeline and detection points. Close outlet valve of lubricating oil pump and dismantle
block plate of oil nozzle at outlet side.
4.8.3 Open rear manhole of reducer to open oil discharging valve of thrust bearing, oil flows into oil
tank. A certain oil of 20mm must be preserved in oil tank, stop oil pump in time when the level is
high to prevent air from entering into oil system.
4.8.4 Connect a flexible pressure bearing tube on side block plate of oil pump outlet, start
lubricating oil pump and pump oil from oil tank into oil vessel.
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4.8.5 Open oil discharging valve at bottom of reducer to discharge residual oil in reducer.
4.8.6 Take off pipe section at suction side between reducer and oil pump and pressure bearing
pipe section between oil cooler and oil separator, including all cables connecting to gear box of
measuring pipe parts.
4.8.7 Dismantle protection cover of coupling of reducer and motor, and dismantle connection bolts.
4.8.8 Motor should be moved away when fishing up reducer from front of reducer, dismantle all
connection bolts of motor and lift motor away. Marks should be made when dismantling motor.
Clean bedplate of motor. Jack reducer to a proper height and fill up round steel under it, then fish
up reducer by lever hoist rooted in workshop. Reducer pulling should be straight and free from
deflection. Loading oil steel and lever bedplate opposite to motor should be dismantled when
fishing up reducer from back of mill, it is not necessary to move motor away. Big block steel plate
should be laid at fishing up position of reducer to keep ground smooth.
Notice: Fill up object under drive plate to steady it after fishing up reducer to ensure safety. Only
jack bolts at fishing up side and two sides on bedplate of gear box should be loosened when
fishing up reducer, reserve the jack bolts on opposite direction of reducer for convenience of
reinstalling at original position. Its better to fish up reducer from mill rear, thus it is not necessary to
move motor.
4.8.9 Move reducer to maintenance ground, discharge gear oil from oil discharging valve. Prepare
all tools, materials, measures and notebooks for records. Clean reducer and ambience, put up
shed above reducing surface to avoid dust.
4.8.10 Dismantle thrust panel of reducer and put it to designated location, clean and check it.
4.8.11 Dismantle thrust pad and bearing seat and put them at designated position; check thrust
pad and seat that should be free from serious abrasion. Repair or replace them according to actual
condition.
4.8.12 Lift and dismantle star gear system, internal gear ring; put them to designated position for
cleaning and check. Abrasion on gear of all gear surfaces should be even.
It should be replaced when crackle, rupture, blow spot or abrasion exceeds 1/3 of design
thickness of gear.
4.8.13 Dismantle input transmission shaft shaft, bearing group and related pipeline; put them to
designated position, heat up wheel-set and pull out wheel-set with special tool. Clean and check it
as a whole.
4.8.14 Dismantle bevel gear and roller bearing with double array cone, column roller bearing for
check and cleaning. It should be replaced when serious blow spot, rust or crackle occurs on
bearing rolling sleeve and roller.
4.8.15 Clean and check transmission shaft. It should be corrected or replaced when bending or
distortion occurs at all axis of rotation; it must be replaced if crackle exists.
4.8.16 Dismantle transmission bevel gear system, check bevel gear and shaft. It should be
replaced when bending or distortion occurs at all axis of rotation; it must be replaced if crackle
exists.
4.8.17 Clean, check and measure all parts after dismantling, record all kinds of data.
4.8.18 Check it completely and clean burr at all parts, measure cooperation dimension.
4.8.19 Heat up spherical roller bearing and install it on bevel gear head. Install the heated
contractile ring onto bevel gear head.
4.8.20 Lay bevel gear with spherical roller bearing vertically and support it, heat up cone roller
bearing and bearing from inside.
4.8.21 Push double array roller bearing into bearing sleeve and install it on bevel gear head
bearing.
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4.8.22 Tighten castle nut to abut double cone roller bearing and oil spattering on shaft shoulder,
and protect it with safety nip
4.8.23 Assemble spacer ring, screw oil sprayer into oil aperture of bearing sleeve
4.8.24 Check axial clearance and radial jump of input shaft.
4.8.25 Push bevel gear bearing into hub of heated bevel gear, assemble bevel gear onto bevel
gear hub of its bearing with bolts and pins.
4.8.26 Heat up column roller bearing and install it onto bevel gear bearing. Install safety ring.
Radial assembling clearance of column roller bearing is 0.05-0.14mm.
4.8.27 Heat up bearing sleeve, assemble double cone roller bearing with spacer ring into bearing
sleeve, and lock it by bearing fixing ring, install regulation ring.
4.8.28 Turn bevel gear shaft assembled with bevel gear for 180, install bearing sleeve and
regulation ring onto bearing bracket, put supporting bolts onto bearing bracket and tighten it.
4.8.29 Heat up cone roller bearing form inside, push bearing bracket with bearing sleeve and the
whole bearing onto bevel gear bearing
4.8.30 Install oil spatter ring and heat up connection ring to about 50 and push it onto gear at
shaft end of bevel gear, tighten middle section with bolts through connection ring and bevel gear
bearing.
4.8.31 Insert gear joint installed with lock ring to connection.
4.8.32 Connect bidirectional oil level ring and gear joint together, press thrust pad into middle
section. Ring and bevel gear shaft connect the middle section with bolts.
4.8.33 Insert gear joint installed with lock ring to connection.
4.8.34 Connect bidirectional oil level ring and gear joint together, press thrust pad into middle
section.
4.8.35 Turn star frame for 1800 (vertical direction)
4.8.36 Install spherical roller bearing to corresponding pre-heated star wheel (three star wheels).
4.8.37 Push three star wheels into star frame (same shaft with aperture) from outside.
4.8.38 Heat up whole surface of star frame put on spacer ring and push star shaft in. Fix star shaft
and star frame with tightening bolts.
4.8.39 Turn star frame for 1800 and connect connection shaft and oil-preserving ring to star frame,
screw threads pin into star frame.
4.8.40 Install sun wheel into star frame, regulate it with temporary retaining ring.
4.8.41 Assemble planetary wheel system to thrust pad bearing bracket in advance and tighten it
with bolts.
4.8.42 Insert transmission sleeve onto thrust panel, tighten it with transmission pin and bolts,
tighten the sealing ring.
4.8.43 Put transmission cover into transmission sleeve and tighten it. Block oil aperture on
transmission sleeve with wire.
4.8.44 Install outer ring of column roller bearing NU230E.M.C3 of horizontal gear bearing into
bearing sleeve of box. Radial assembling clearance of column roller bearing NU230E.M.C3 is
0.05-0.14mm, radial assembling clearance of double array cone roller bearing 34.4X/DF is
0.03-0.09mm and axial assembling clearance is 0.12-0.33mm.
4.8.45 Clean and check gear ring and all parts whether has burr, crackle or not. Clean and
measure new part if it is necessary to replace new part.
4.8.46 after heating up box, put inner gear ring in, push proper key in between box and inner gear
ring.
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4.8.47 Regulate key to make it proper and be free from clearance
4.8.48 Install bevel gear shaft ( shaft) with bearing bracket. Installed the assembled bevel gear
into outer ring of column roller bearing, connect corresponding inner pipeline on these parts.
4.8.49 Install bevel gear shaft ( shaft) and bearing group. Radial assembling clearance of
spherical roller bearing 24136M.C3 is 0.12-0.22mm, radial clearance of double array cone roller
bearing 31330X/DF is 0.05-0.11mm and axial assembling clearance is 0.08-0.22mm.
4.8.50 Screw eccentric actuator upwards (markers should be made), insert whole bearing group
into tank.
4.8.51 Turn eccentric actuator for 90 towards zero, turn it lightly and regulate joggling clearance
of gears.
4.8.52 Install regulation ring, check joggling area. Joggling area of gear must be 50% bigger than
gear length, clearance between two joggling gear should not exceed 0.15-0.2mm.
4.8.53 Connect corresponding pipeline, including exterior oil returning pipeline.
4.8.54 Install planetary wheel system.
4.8.55 Introduce whole start frame into rim of inner gear ring, regulate joggling of gear and support
it with thin steel plate.
4.8.56 Check the clearance of sun wheel and star frame. Radial assembling clearance of spherical
roller bearing 23138M.C3 is 0.08-0.22mm. Clearance between supporting bolts and star frame is
7mm.
4.8.57 Connect corresponding inner pipeline.
4.8.58 Put thrust pad bearing bracket with radial sliding bearing that is assembled in advance into
box and then tighten it, install corresponding pipeline.
4.8.59 Install thrust pad.
4.8.60 After fixing round pad with column pin, put retaining ring on thrust pad bearing bracket and
then tighten it.
4.8.61 Install high pressure tube with fixing device.
4.8.62 Install, regulate thrust panel with dope contacting method.
4.8.63 Put thrust panel on coupling shaft and thrust pad bearing, check thrust panel with dope
contacting method (turn thrust panel slowly through circumrotation of shaft). Remove martial if it
necessary. Check contacting area. Differential height of every thrust pad should not exceed
0.025mm.
Grind or modify supporting surface (inclined surface) manually if it is necessary.
4.8.64 Dismantle thrust panel, clean and lubricate sliding surface and lubricate tile and bearing
seat.
4.8.65 Lower planetary system, check clearance between supporting bolts and planetary system.
4.8.66 Install and tighten gasket and hexagon nuts with safety nip.
4.8.67 Check coupling center, change radial fluctuating error according to proportion of measured
radius r if r200mm. Radial jumps of coupling 0.1mm and axial jump 01.mm.
4.8.68 Check pipeline and accessories, sealing surface should be strict and free from leakage.
4.8.69 Connect all related pipeline.
4.8.70 Paint appearance of reducer
4.8.71 Clean site; there is no abnormal sound during reducer trial run, vibration value should be no
higher than 0.02mm. Pressure and flow of cooling water and lubricating oil at oil station should be
normal, corresponding pipeline should be free from leakage.
95
4.8.72 Painting on equipment is complete, site is clean and conclude work permit ticket after it is
qualified.
5 Safety, Health and Environmental Protection
5.1 Accident Countermeasures
5.1 Equipment isolation measures must be taken for fire fighting and equipment overhaul of
pulverizing system.
5.2 Related regulations of anti-explosion of boiler pulverizing system in Code of Safety Operation
in Power Industrial (Thermal and Mechanical Part) must be strictly executed.
5.3 Clean powder leaking points and clean the leaked powder. Fire is prohibited during cleaning
coal powder.
5.4 Coal mill outlet temperature should be strictly controlled within regulated range, outlet air
temperature should not exceed 80.
5.5 Strengthen and improve management of Two tickets and three rules, make feasible work
permit ticket rules, work with no work permit ticket is prohibited, all of which makes work permit
rules be really important guarantee of safety of equipments and maintenance personnel body.
5.6 Supplementary regulations of Thermal and Mechanical Work Permit Rules in Code of Safety
Operation in Power Industrial, regulations for work permit issuer, approval and work principal must
be strictly executed. During execution of work permit ticket, work approval should check safety
measures listed in work permit ticket, all the safety measures have been rightly executed. During
work permit, regulation of work approval and work principal must be at site for checking safety
measures before starting repair must be carefully executed.
5.7 Do analysis of dangerous points pre-control well. Safety measures ensuring personnel body
and equipment operation must be carefully executed.
5.8 Strengthen safety management and training for periphery maintenance unit.
6 Safety
6.1 Working suits and safety protection articles must be worn as per Safety Rules when entering
into site. Before entering into side for maintenance, thermal and mechanical work permit ticket
must be issued, measures for cutting power supply of mill motor and coal feeder must be executed
together with operators, warning plate of No Close should be hung on equipment. Coal, powder,
air and fire fighting steam entering into mill should be completely isolated. Effective measures
should be taken to avoid operation by mistake, such as install a lock.
6.2 One principal must be designated when two or more are working.
6.3 Sufficient lighting should be set at site and portable light is used for indoor lighting. Check wire
and welding electric welding wire whether they have dilapidation and bareness or not.
6.4 Electric-driven tools must be checked and qualified. Welding personnel and working personnel
using electric-driven tool should wear insulated shoes, insulated plate should be laid, all of which
should comply with requirements of Safety Rules.
6.5 Clean all the coal powder completely inside mill before starting work; gasoline is prohibited for
cleaning.
6.6 Close outlet and inlet gate valves of mill to avoid dropping of personnel and articles.
6.7 Safety belts and tools must be rightly used at high altitude; transportation of materials must
comply with regulations of Safety Rules.
6.8 Crane, rope and tools must be checked and qualified before using; operators should be who
have been specially trained.
6.9 Clean coal powder in mill before electric welding, working personnel suits should comply with
working requirements. Check working location around before stopping work to avoid kindling.
There should be no air leakage at oxygen tube and acetylene tie-in. Special person should be sent
96
for supervision during work with fire.
6.10 Fire fighting equipment should be sufficiently prepared at site.
6.11 Protection glass must be worn when using grinding tools. Watch grinding part straightly, no
working personnel should be at direction of electric sparkle direction. Any defect is allowed for
grinding wheel and head.
6.12 During welding work on mill plate and air ring, earth current may damage thrust pad and
reducer gear; this kind of work should be avoided. If it must be done as above, individual earth
wire should be connected. Creepage part of welding wire contacting with mill plate should be
avoided when there is welding on sleeve or other parts. Welding earth wire should connect to
pieces to be welded, long distance loop is prohibited.
6.13 Check and amount personnel and tools when work is completed, reclaim residual materials
and eliminate kindling, clean the working site.
6.14 Recover dismantled guardrail, protection cover and channel cover plate when work is
completed.
6.15 Clean the site after work is completed, no kindling is left.
7 Healths
7.1 Measures must be taken when contacting with chemicals that is poisonous to human body,
deleterious or with pungent smell.
7.2 Fine ventilation equipments must be prepared to avoid asphyxiation in tank when entering into
vessels or air boxes.
8 Environmental Protections
8.1 Wasted oil must be poured into designated oil barrel and can not be poured casually.
8.2 Wasted or residual chemicals must be put at designated position.
8.3 Work completed, material is cleared up and site is clean should be realized after work is
completed.
97
Chapter Boiler Coal Feeder Overhaul
2.0 Applicable Scope and Quoted Materials:

This chapter is applicable for EG 2490 weighing type coal feeder (produced by Shenyang Shi
DaoKe Electric Power Equipment Co., Ltd.) maintenance and overhaul and to offer references and
guides for the maintenance personnel.
Quoted materials: EG 2490 Weighing Type Coal Feeder Storage, Installation, Maintenance
and opration (Combined book) Shenyang Shi DaoKe Electric Power Equipment Co., Ltd
2.1 Equipment Brief Introduction and Parameter
2.1.1 Coal Feeder Brief Introduction
Six (6) electronic weighing type coal feeders produced by Shenyang Shi DaoKe Electric
Power Equipment Company limited are equipped for each boiler, which mainly consists of coal
feeder body, belt, drive device, cleaning transportation chain, drive and transmission device, coal
feeder electronic control device and Micro-processor control device. During work, raw coal drops
from raw coal hopper to transportation belt of coal feeder, which transports raw coal to inlet pipe of
chute under bringing of transmission device. Regulate tension degree of belt through tightening
shaft and regulate coal feeding amount through running speed of belt.
2.1.2 Parameter, Capacity
2.1.2.1 Equipment name: electronic weighing coal feeder
Type: electronic weighing type
Model: EG2490 type, output regulable range: 11110t/h

Belt speed when maximum output: 0.26 m/s
Quantity: Six (6) coal feeders are equipped for each boiler, 12 sets installed for this project.
Coal feeder belt width: 840 mm
Feeding coal distance (coal feeder inlet & outlet centerline distance): 2500 mm (interim)
Nominal height with interface of raw coal bunker outlet: 20.5m (interim)
Nominal height with interface of coal mill inlet: 10.150m (interim)
Interface dimension of raw coal bunker outlet: 94010 (interim)
Interface dimension of mill inlet: 72010 (interim)
Chute inlet:
Length_1890_mm, Pipe diameter (outer diameter) 1000629mm, wall thickness

10mm, Material: Stainless steel
Chute inlet:
Length_4150_mm, Pipe diameter (outer diameter) 629mm, wall thickness 10mm,
Material: Stainless steel
Coal inlet flange inner diameter (inlet coal valve inner diameter):_929_mm, material:
Q-235A
Coal outlet flange inner diameter (outlet coal valve inner diameter):_929_mm, material:
Q-235A
98
2.1.2.2 Interface dimension with mill: outer diameter 720 (final dimension of institute is
prevailed)mm, wall thickness _10_mm
2.1.2.3 Main drive motor
Type: Y3-4P
Power: 3kW
Power supply: 380V, three phases 50Hz
Full load start torque: 1132Nm
2.1.2.4 Motor of cleaning chain
Model: Y0.37-4P
Power: 0.37kW
Power supply: 380V, three phases 50Hz
2.1.2.5 Motor sealing air
Sealing air pressure (outlet differential pressure with mill): 500Pa
Sealing air amount: 10Nm3/min
2.1.2.6 Block excluding air:
Block excluding air pressure: >0.5MPa
Block excluding air amount: 0.2Nm3/min
2.1.2.7 Required minimum coal column height of sealing: 1.5 m
2.1.2.8 Coal gate valve purging air (if there is):
Purging air pressure: 0.5MPa
Purging air amount: 0.2Nm3/min
2.1.2.9 Fire fighting steam parameter:
Pressure: >0.4 MPa
Temperature: <250
Coal feeder body weight: 4000 kg
Inlet coal gate valve weight: 1000 kg
Outlet coal gate valve: 800 kg
Inlet chute and other accessories weight: 310 kg
Outlet chute and other accessories weight: 1400 kg
Coal feeder maximum weight when charged with coal: 8500 kg
2.1.2.10 Raw coal pile specific gravity: 0.9381 t/m3 (design coal) 0.8491 t/m3 (checked coal)
2.1.3 Basic performance
Life of coal feeder should be no less than 30 years.
Coal feeder can supply coal continuously and evenly, weighing is right and reliable, regulate
coal feeder output quickly and rightly according to boiler combustion control system to make actual
coal feeding amount match with boiler load. Coal feeder can start with full load.
Coal feeder measuring precision: 0.25%
Coal feeder control precision: 1%
99
Running with no fault: 15000h
Anti-explosion of coal feeder is designed as per 0.35Mpa.
Coal feeder has capacity measuring function, when electronic weighing system is in fault, it
can be converted to volume measuring type and send alarm signal.
During normal operation of coal feeder, noise at place 1m away from shell should not
exceed 85dB (A).
2.1.4 Structure and System Configuration
Coal feeder shell, inlet & outlet flashboard valve, inlet & outlet chute and regulable connector
are pressure resistant design with pressure resistant degree of 0.35Mpa. Ensure sealing
performance fine and no powder leakage.
Sealing air is even and regulable, avoid upward return of hot air powder in mill effectively and
blowing coal on belt away.
Watch window is set in coal feeder shell and explosion-proof spot light are set in coal feeder
shell for watching operation condition inside shell. Compressed air nozzles are installed on watch
window for cleaning dust from inner surface, thus it is not necessary to open valve or stop coal
feeder.
2.1.5 Coal Transportation Machine
Main drive roller has function of anti-sliding and anti-deflection.
Driven roller has self-cleaning function.
Rubber belt tensioning device is set for coal feeder to keep constant tension of rubber belt
and ensure stable measuring precision. Tensioning device should be convenient for regulation.
Measures should be taken to avoid rubber belt deflection.
Coal feeders are equipped with functions of supervision and alarming of breaking coal,
blocking coal and insufficient coal.
Cleaning device is set at lower section of coal feeder.
Inlet and outlet chute of coal feeder should ensure no coal blocking and wall thickness
should be no less than 10mm, materials of all metal parts contacting with coal flow adopts
stainless steel.
Inlet and outlet coal gate valves are able to open or close manually or automatically, its
action should be agile and reliable, valve position indication is set.
During coal block, coal feeder can turn in reversal to unload coal and necessary emergent
coal discharging device is also set.
Coal feeder is equipped with sealing air interface and fire fighting interface.
Valve convenient for maintenance id set for coal feeder, measuring transportation part can
be dismantled with special tools and can be drawn out wholly from shell for the convenience of
maintenance.
Coal feeder weighing measuring device consists of weighing type transducer, weighing roller
and measuring roller. Weighing type transducer is anti-dust and anti-explosion type and can work
normally in abominable environment.
Coal feeder rubber belt is fire resistant, high intension, continuous type rubber belt, ring has
no tie-in and its permanent extension rate is less than 1, wave baffle with skirt at two sides can
prevent coal powder from leaking out from belt.
Inside and outside cleaning devices are set for coal feeder to remove coal powder used on
rubber belt surface. Cleaning device scraper material should not damage rubber belt.
Scraper chain cleaning machine is set for coal feeder and installed on shell bedplate under
rubber belt for cleaning coal removed from rubber belt and coal dropped during running, all of
100
which makes shell bottom free from accumulated coal.
Air sealing of inlet and outlet motor-driven coal gate valve of coal feeder is fine and water
discharging interfaces are set. Materials of all metal parts contacting with coal flow adopts
stainless steel, structure design of coal gate valve meets the requirements of NFPA and can bear
0.35MPa explosion pressure. Motor-driven coal gate valve has self-cleaning function, and could
not be blocked by coal particles after repeat operation; it can be closed or opened easily by
manual. Inlet coal gate valve inner diameter should not be less than 900mm and outlet coal gate
valve inner diameter should be no less than 600mm.
2.1.6 Motor
Drive device speed regulation control mode: frequency conversion speed regulation
(transducer inlet)
Motor voltage: 380V
Motor protection grade is: IP54

Motor has proper position for connecting fixed earth lead.
Motor outlet box direction, position: from motor to coal feeder, outlet box is at left side.
Maximum noise at place 1.5m away from motor shell and 1.2m from operation platform
should not exceed 85dB(A).
Motor is with grade F insulation system, sealing or static winding of welding sealing.
Motor bearing structure is sealed, be able to isolate feculence and water and lubricant can not
enter into winding.
Bearing temperature measuring element adopts double supporters type and is reliably
installed.
Down-lead and drive line of temperature detection element are separated and are led to
junction box separately.
2.1.7 Reducer transmission is stable and reliable and be with nine sealing and oil leakage.
2.1.8 Transducer AC Power Supply Parameter
Rated voltage 380V
Voltage normal variation range +10%~-10%
Bus line voltage when motor start automatically as a whole 60% Un
Bus line voltage when high voltage and low voltage start in series 55% Un
Rated frequency 50Hz
Frequency variation range +3%~-3%
short circuit current at 380V bus line side 50kA (effective value)
Neutral point Non-earth system
2.1.9 DC Power Supply: DC drives 220V, DC control 110V.
Transducer has the function of cutting off power for locking within limited time, that is, power
supply recovers after a long time of power cutting of bus line, and transducer will not start
immediately.
Current limit control, limit maximum current be within 1.0~1.1 rated value (including starting
and speed regulating), that is constant torque control.
Emergency button and current signal can satisfy remote transmission.
It is able to start automatically after instantaneous power cutting and continue state before
power cutting off to satisfy current requirement.
Protection functions of transducer, motor short circuit and overload are completed inside
101
transducer, the buyer supply power to transducer through air breaker.
No harmful effect should happen to equipments at state grid side, such as insulation damage,
protection control system error etc.
Harmonious wave produced by frequency conversion speed regulation system not only can
satisfy regulation of GB/T 14549 Power energy quality common grid harmonious wave, but also
GB/T13926 electromagnetic compatibility of industrial process measuring and control device and
related electromagnetism compatibility requirement of GB/T14598. 9GB/T14598.10
GB/T14598.13GB/T14598.14.
Equipment supplier supplies proper fittings to allow many transducers being connected in
parallel on the same bus line.
Transducer main technical parameter
Input rectifying bridge 12 impulse or higher
Inverter type Voltage source type
Inverter power element IGBT or IGCT
Auxiliary power supply 380V AC
Control mode PWM or DTC
Output voltage sine wave
Output frequency 050Hz
Cooling type air cooling or forceful air cooling
Isolation power supply part Fiber-optic Cable
Protection grade IP54
Transducer control system adopts digital microprocessor controller. There is operation
interface on transducer cabinet door, there are touching keyboard and LCD/LED display on
operation interface.
There is start, stop transducer on cabinet door for regulating frequency.
Be with fault diagnose display.
2.1.10 Instrumental Meters and Control
At least there are remote instructions inputs on cabinet of control box and drive box of coal
feeder:
Start coal feeder
Stop coal feeder
Control coal feeding amount (4-20mADC)
At least there are remote instruction outputs on cabinet of control box and drive box of coal
feeder:
Coal feeder run, stop state
Coal feeder current (4-20mADC)
Cleaner run, stop state
Belt conveyor motor fault
Cleaner motor fault
Instantaneous coal feeding amount
Accumulated feeding coal amount
Coal flow abnormal in chute at inlet side of coal feeder (coal block)
102
Coal flow abnormal in chute at outlet side of coal feeder (coal block)
Coal feeding rate error high
Belt lacks coal (coal feeding stopped)
Coal feeder is blocked by coal
Over-high temperature in coal feeder
Local or remote control
Sequence control fault
Cubage running signal
Belt conveyor normal running signal
Rubber belt reversal running signal
Coal feeder at least has following interlock protections:
Coal feeder stops automatically according to signal of take two from three
when chute at outlet of coal feeder is seriously blocked
When belt conveyor motor is in fault, it cuts off power supply automatically
When cleaner motor is in fault, it cuts off power supply automatically
Inlet & outlet gate valve electric-control box of coal feeder at least have following functions:
Manual control of local electric control box
Open, close coal gate valve
Locally manual or remotely manual (automatic) transfer of control mode
Local electric control box display: coal gate valve full open, full close
Coal feeder electric control box at least has remote instruction input of opening, closing coal
gate valve:
Coal feeder electric control box at least has following instruction outputs:
Coal gate valve full open, full close
Coal gate valve suffocate to open, close (over torque)
On-off output supplied by seller is passive junction signal, its junction volume is no less than
220V AC 3A, 220V DC 1A.
2.1.11 Performance Guarantee
Output regulation range: 11110t/h

Coal feeder measuring precision: 0.25%
Coal feeder control precision: 0.5%
Noise (1m away) 75dBA

Power consumption: 8kW
2.1.12 Equipment Radius and Interface Regulations
On coal feeder, from coal bunker outlet flange connection to connection of chute in middle of
mill, including (but not limited):
Coal feeder proper (including motor, reducer, electronic weighing system)
Electric control box, drive box
Inlet, outlet coal gate valve (including electric-driven device and control box)
103
Inlet and outlet chute
Coal flow supervisor
Regulable connector
Counter flange and tightening fittings are offered to all flange interfaces
Maintenance chain
Reversal turning material unloading slot
Maintenance platform car
Spare parts
Special tools
2.1.13 Equipment Component
Production
No. Name Specification Unit Qty Manufacturer Remark
area
Coal feeder proper (pressure
resistant sleeve, roller coal
flow molding device, roller,
sleeve, belt, anti-explosion
lighting device, cleaning
chain, coal smashing hole,
1 EG2490 set 6 Shenyang STOCK
tensioning device,
maintenance valve, watch
hole, sealing air interface,
manual valve coal sampling
device, all flange and bolts
tightening piece)
Coal feeder control cabinet
(integrated with drive
cabinet)
set 6
Mainly contain following
parts: piece 6
196 microprocessor piece 6
controller
piece 6
Integer
2 Transducer 196NT MPC America STOCK
set 6 import
Display panel and keyboard
set 6
Power supply plate
set 12
A1 cardinput card
A2 cardFeedback card
A/D converter
Inlet coal gate valve
(including motor-driven
3 device, control box, raw coal 36-RR-VB set 6 Shenyang STOCK
bunker outlet flange and
tightening fittings)
Outlet coal gate valve
4 (including motor-driven 24-RR-VB-SP set 6 Shenyang STOCK
device, control box)
104
Production
area
Clean chain drive motor and
5 AE-100 set 6 Zhejiang JIE
reducer
Rubber drive motor and
6 set 6 Zhejiang JIE
reducer
Outlet coal block alarm
7 set 18 America STOCK
device
8 Belt breaking coal alarm set 6 America STOCK
Inlet, outlet chute pipe
9 Ae-100 set 6 Shenyang STOCK
ultrasonic coal flow inspector
Temperature alarm device Special
10 set 6 Wuxi instrumental
meter
11 Rotating measuring detector set 6 America STOCK
12 Maintenance chain set 6 Shenyang STOCK
Regulable connector (inlet,
13 set 6 Shenyang STOCK
outlet)
14 Inlet and outlet chute set 6 Shenyang STOCK
Electronic weighing system set 6
Mainly including following
parts
Weighing sensor piece
12
15 America STOCK
Weighing roller piece 6
Bearing piece 12
Sealing ring piece 24
Weighing lever
piece 12
subassemblies
piece
2.1.14 Special Tools
Production
area
Plane calibration 2 Special tool
1 lever (measuring piece Shenyang STOCK for
feeler gauge) measuring
Detector 2
2 (nominal piece America STOCK
detector)
3 Cable of detector piece 2 America STOCK
4 Glisten paper piece 16 America 3M
5 Nominal poise piece 2 Shenyang STOCK
105
Production
area
Roller wheel Special tool
6 piece 1 Shenyang STOCK
dismantling seat for
maintenance
7 Roller lifting lever piece 1 Shenyang STOCK
Roller wheel
connection lever
(extension guide
track)
9 Tool box piece 1 Shenyang STOCK
Reversal coal
discharging slot
Maintenance
platform car
2.1.15 Imported Piece List
Production
area
Electric weighing
system
Mainly including set 6
following parts:
Weighing sensor piece 12 Integer
1 America STOCK
Weighing roller piece 6 import
Bearing piece 12
Sealing ring piece 24
Weighing lever set 12
subassemblies
outlet coal block
2 set 18 America STOCK
alarm device
Coal feeding control
system: 6
196 microprocessor
controller
set 6
Transducer (AB)
piece 6
Display panel and Integer
3 keyboard 196NT MPC piece 6 America STOCK
import
Power supply plate piece 12
A1 card (input card) set 6
A2 card (feedback set 6

card) Set 12
A/D converter
Belt breaking coal
4 Set 6 America STOCK
alarm
106
Production
area
Speed measuring
5 Set 6 America STOCK
device
6 Bearing Set 6 Sweden STOCK
Detector (nominal
7 Piece 2 America STOCK
detector)
2.1.16 Spare Parts
2.1.16.1 Spare parts brought with machine
Production
area
1 Air breaker set 1 France Schneider
2 Bearing set 1 Sweden STOCK
Scraper chain
3 Group 2 Shenyang STOCK
subassemblies
4 Sealing ring set 1 Shenyang STOCK
Middle relay Piece 2 France Schneider
AC contactor Piece 1 France Schneider
Hot relay Piece 1 France Schneider
Knob switch Piece 2 France Schneider
Transformer Piece 1 America STOCK
2.1.16.2 Recommended spare parts for three-year business operation

Specifica Production
No. Name Unit Qty Manufacturer Remark
tion area
1 Weighing 2 (Respective
transducer Piece America STOCK one at left
and right)
2 Coal feeder belt 1
set Zhejiang JIE
motor transducer
3 Coal feeder belt 2 Xiangshan
Piece Zhejiang
rubber
4 Scraper chain 2
set Shenyang STOCK
subassemblies
5 Weighing roller Piece 2 Shenyang STOCK
6 Clean motor 1
reducer with set Germany FLENDER
scraper
7 Rotating speed 1
set America STOCK
measuring detector
8 196 piece 1 America STOCK
microprocessor
107
controller CPU
2.2 Overhaul Sort, Cycle and Period
Sort Cycle Period
Major overhaul 3 years 60 days
Minor overhaul 1 year 15 days
2.3 Overhaul Items
2.3.1 Coal Feeder Major Overhaul Items
2.3.1.1 Clean surplus coal in coal feeder and loosen tightening shaft.
2.3.1.2 Check and repair drive shaft, star gear and bearing.
2.3.1.3 Check and repair tightening shaft and bearing.
2.3.1.4 Replace all the chain, scraper and scraping plate.
2.3.1.5 Replace chain bracket.
2.3.1.6 Replace coal feeder upper and lower bedplate.
2.3.1.7 Weld coal feeder box and lower section of raw coal hopper by replacing.
2.3.1.8 Dismantle and repair reducer box.
2.3.1.9 Dismantle and repair manual valve of coal feeder fire fighting steam.
2.3.1.10 Check and align coupling.
2.3.1.11 Trial run of equipment with empty load
2.3.2 Coal Feeder Minor Overhaul Items
2.3.2.1 Check inside of coal feeder.
2.3.2.2 Check coal feeder chain and regulate degree of tightness of chain.
2.3.2.3 Check and fill for reducer box.
2.3.2.4 Check and fill oil for safety coupling.
2.3.2.5 Check box and weld thinned part due to abrasion by replacing.
2.4 Maintenance Overhaul, Process Method and Quality Standard
2.4.1 Preparation
2.4.1.1 According to operation condition and technical records of previous overhaul, confirm
abrasion and damage degree of all parts, make sure important overhaul technical plan and
technical measures arrangement.
2.4.1.2 Spare parts must be prepared for ensuring replacing parts in time during overhaul.
2.4.1.3 Prepare all kinds of special tools, common rolls and measures for overhaul.
2.4.1.4 Check and test all lifting equipments and tools according to regulation.
2.4.1.5 Power supply, lamps and lanterns, illumination power supply should be arranged at site.
2.4.1.6 Equipment floor plane should be set during overhaul.
2.4.1.7 Prepare complete whole set of overhaul record tables and cards.
2.4.1.8 Clean site, arrange required parts, dismantling and special ground for repairing of main
parts according to floor plan.
2.4.1.9 Prepare sufficient oil storage barrel, crosstie and other things.
2.4.1.10 Issue thermal and mechanical work permit ticket.
108
2.4.2 Overhaul Process and Process Method
2.4.2.1 Coal Feeder Dismantling
2.4.2.1.1 Work only can be done after confirm that power supply of mill and coal feeder, sealing air
source and fire fighting steam source are cut off and temperature inside coal feeder and
environmental temperature 40.
2.4.2.1.2 Dismantle all related pipeline of coal feeder and mark the positions for the convenience
of reinstalling.
2.4.2.1.3 Open the front and rear maintenance doors and at side of the coal feeder.
2.4.2.1.4 Dismantle weighing device and check it.
2.4.2.1.5 Draw out transmission belt and cleaning chain, take off all transmission and driven roller
and weighing roller, replace them if it is necessary.
2.4.2.1.6 Enter into coal feeder, check abrasion of anti-abrasion lining plate, and replace it if it is
necessary.
2.4.2.1.7 Dismantle belt drive device and drive device of cleaning chain, check abrasion of inner
transmission part and then decide whether to replace it or not.
2.4.2.1.8 Check outlet and inlet gate valve of coal feeder, check sealing and agility of sealing air
and fire fighting steam valve.
2.4.2.2 Coal Feeder Reassemble
2.4.2.2.1 Reinstall transmission and driven roller and weighing roller.
2.4.2.2.2 Reinstall cleaning chain and belt.
2.4.2.2.3 Install belt and cleaning chain drive device, regulate belt tension and running track.
2.4.2.2.4 Install and regulate weighing device.
2.4.2.2.5 Reinstall outlet and inlet gate valve and sealing air, fire fighting steam valve of coal
feeder.
2.4.2.2.6 Clean inside of coal feeder.
2.4.2.2.7 Close maintenance valve of coal feeder.
2.4.2.2.8 Connect related lines for coal feeder.
2.4.2.2.9 All oil filling parts are as following:
English
Letter symbol
A- A-face to face
B- B-double surfaces
C- C-two positions
109

-
B-
C-
2.4.3 Overhaul Quality Standard

2.4.3.1 Coal Feeder Quality Standard
2.4.3.1.1 It should be replaced if coal feeder belt surface is seriously scrapped or burned.
2.4.3.1.2 It should be replaced if abrasion of anti-abrasion lining plate inside coal feeder exceeds
1/2.
2.4.3.1.3 It should be replaced if crackle or abrasion of drive chain exceeds 1/2 of original
dimension.
2.4.3.1.4 It should be regulated if inner gear joggling of drive device occurs improperly, all stages
of gear should be free from teeth dropping or crackles; abrasion of gear should not exceed 30% of
original gear, joggling area of gear is in the middle and has no deflection. Gear contacting should
be no less than 75% in length and no less than 60% in height.
2.4.3.1.5 Bearing is free from blow spot, crackle or serious abrasion.
2.4.3.1.6 Welding by placing can be done for drive shaft and tensioning shaft if there is only slight
abrasion, any bending is not allowed.
2.4.3.1.7 Weighing roller and weighing span roller at two sides should be in the same plane, its
plane degree error should be no bigger than 0.05mm to ensure accurate measuring precision. A
0.127 gasket should be inserted between three contacting surfaces of two weighing span roller,
plane feeler gauge and weighing roller when regulating weighing roller.
2.4.3.1.8 The sign of proper tensioning stress is that, sink degree of chain from drive chain wheel
to supporting plate of the first chain is 5cm.
2.4.3.1.9 A 3.175cm clearance should be preserved between roller coupling and half coupling on
drive shaft when replacing drive roller.
2.4.3.1.10 Belt should aim at centerline before tensioning it, make V guide track at back of belt
embed all roller and grooves of roller.
2.4.3.1.11 Down-lead should be cut off when replacing steel wire and make it extrude about 5cm
at two gaps.
2.4.3.1.12 sealing air pressure of coal feeder is 6mmHg higher than inner pressure of mill, single
differential pressure should not be higher than 25mmHg.
2.4.3.2 Whole Set Running
2.4.3.2.1 Whole set running vibration value should be less than 0.05mm and turning part
temperature should be lower than 700C.
2.4.3.2.2 System is free from air leakage, powder leakage and oil leakage; all pipelines are
smooth; pipelines and their accessories are free from leakage.
110
2.4.3.2.3 Belt and cleaning chain running trace is normal.
2.4.3.2.4 Bolts are evenly tightened with same direction and anti-looseness device is equipped.
2.4.3.2.5 Paint and insulation of equipments is complete and all signs are clear and complete.
2.5 Safety, Health and Environmental Protection
2.5.1 Safety
2.5.1.1 Working suits and safety protective articles should be worn according to Safety Rules
when entering into site.
2.5.1.2 One principal must be conformed when two or more than two personnel are working.
2.5.1.3 Sufficient lighting should be prepared at site and complies with Safety Rules.
2.5.1.4 Creepage protector must be used when using electric tools and regulations for using
electric tools must be complied. Tools or apparatus with defects can not be used.
2.5.1.5 Clean coal powder inside coal feeder completely before starting work. Gasoline is
prohibited to clean parts.
2.5.1.6 Inlet and outlet gate strobes should be closed to avoid personnel or article dropping.
2.5.1.7 Safety belts, tools must be rightly used when working at high altitude, transportation of
2.5.1.8 Comply with Safety Rules of lifting and conveying carefully.
2.5.1.9 Recover the shield, protective cover and groove cover plate that dismantled during
overhaul after work is completed.
2.5.1.10 Check and amount personnel and tools after work, reclaim residual materials, clear up
2.5.1.11 Clear up flammable and explosive impurities at site.
2.5.1.12 Electric welding earth wire is on parts to be welded, long distance loop is not allowed.
2.5.1.13 sufficient fire-fighting apparatus should be prepared at site.
2.5.1.14 Special person should be sent for supervision when there is work with fire.
2.5.1.15 Clean the site after work is completed and no kindling is left.
2.5.2 Health
2.5.2.1 Measures must be taken when contacting with chemicals that is poisonous to human body,
2.5.2.2 Fine ventilation equipments must be prepared to avoid asphyxiation in tank when entering
into vessels or air boxes.
2.5.3 Environmental Protection
2.5.3.1 Wasted oil must be poured into designated oil barrel and can not be poured casually.
2.5.3.2 Wasted or residual chemicals must be put at designated position.
2.5.3.3 Work completed, material is cleared up and site is clean should be realized after work is
completed.
111
Chapter Boiler Raw Coal Hopper Maintenance Regulation
3.0 Applicable Range and Quoted Material

This chapter is applicable for boiler coal hopper maintenance and overhaul and to offer
references and guides for the maintenance personnel. Quoted materials: DL/T748.4 Thermal
Power Plant Boiler Overhaul Guide Rules Part Four Pulverizing System Overhaul
3.1 Brief Introduction and Parameter
Six hyperbola steel coal hoppers are set for boiler, each coal hopper height is 19.7m, inlet
diameter of raw coal hopper is 8.40m and outlet diameter is 0.95m, inner lining stainless plate in
wimble =3mm, outer layer wall thickness is 12mm and effective capacity is 593m3. Its structure
consists of steel frame girder, sleeve wall, vertical rib, horizontal rib and connection plate.
3.2 Maintenance Sort, Cycle and Period
Sort Cycle Period
3.3 Maintenance Items
3.3.1. Major Overhaul Items of Raw Coal Hopper
3.3.1.1. Check raw coal hopper abrasion completely.
3.3.1.2. Replace raw coal hopper.
3.3.2. Minor Overhaul Items of Raw Coal Hopper
3.3.2.1. Check inside of raw coal hopper.
3.3.2.2. Mend by welding for thinned parts due to abrasion.
3.4 Maintenance Process Method and Quality Standard
3.4.1 Built reliable scaffold.
3.4.2. Measure wall thickness of raw coal hopper, check abrasion of steel frame girder, sleeve wall,
vertical rib, horizontal rib and connection plate. Abrasion should not exceed 2/3 of original
thickness and free from crackle; it should be replaced if there is no serious rust.
3.4.3 When mend raw coal hopper seat surface by welding, both two side should be welded
symmetrically; when mend large area by welding and replacing, two welders should weld at the
same time to avoid distortion. Welding line should be smooth and free from slag inclusion,
distortion and crackle. Welding rod should be in consistent with material of steel to be welded, the
material of replacing steel plate and original steel plate should be the same, wall surface should be
smooth and free from powder after welding.
3.5.1 Safety
3.5.1.5 Before cleaning raw coal hopper, contact with operators to use out raw coal in hopper, lift
coal plough. Hang warning plate of Working, No Operation, ensure raw coal hopper outlet gate
plate is closed according to safety measures in work permit ticket, cut off power supply of coal
112
feeder.
3.5.1.6 When cleaning raw coal hopper, pay attention to temperature variation in hopper to avoid
spontaneous combustion explosion of coal powder.
3.5.1.8 Dry-ice fire extinguisher should be prepared before entering into raw coal hopper for
emergency.
3.5.1.9 When cleaning raw coal hopper, working personnel should wear respirator and glove;
sleeves should be tightened with belts. Working personnel can only enter into hopper after all
safety measures are executed according to working regulations and there should be two
personnel supervise outside hopper.
3.5.1.10 only 12V anti-explosion portable light is allowed for lighting in raw coal hopper, rubber line
and lamp insulation should be fine
3.5.1.11 Smoking and ignition must be prohibited when cleaning raw coal hopper and no
flammable articles can be bright into hopper.
3.5.1.12 complete ventilation should be done before entering into raw coal hopper, temperature in
hopper should not exceed 40. Working personnel can only enter into hopper for work after
detecting and confirming that CO content is not threatening personnel health. When spontaneous
combustion of left coal powder occurs in raw coal hopper, working personnel should exit timely,
seal raw coal hopper and put out a fire with fire fighting steam or carbon dioxide or pour with no
pressure water source.
3.5.2 Health
completed.
Chapter Air Compressor Overhaul

4.1.1 Air compressor brief introduction
Common system instrumental and meter using air and air for unit compressor are supplied by
three (3) D132 no oil screw stem air compressors produced by Shanghai CompAir Compressor Co,
Ltd. Three (3) D90 no oil screw stem air compressors are equipped for supplying compressed air
for maintenance. As variation of air consumption, air compressor will load and unload
automatically to adapt air amount variation of transportation system.
4.1.2 Air compressor main performance parameters
No. Name Unit Technical parameter Remark
113
No oil screw air
Screw air compressor
compressor
1 Model D132
Air suction
parameter is
2 Air discharging amount Nm3/min 20.59 converted into
suction amount of
standard state
3 Air inlet pressure MPa(a) 0.8
4 Environment temperature 0-45
5 Air discharging pressure MPa(g) 0.85

6 Cooling type Water cooling type
7 Air discharging temperature 45
8 Compression stage One stage

Flexible direct
9 Transmission type:
connection type
10 Rotating speed r/min 13598
11 Oil content at outlet of air ppm 0
12 Shaft power kW 126
13 Specific power Nm3/kW 5.92
Cathode and anode rotor type
14 CompAir D type line
line
Rear cooler output
15
temperature:
16 Cooling water
Cooling water quality Common industrial
requirement intenerated water
Cooling water inlet <40

temperature
Cooling water maximum flow m3/h 9.78
Cooling water inlet water 0.6
MPa
pressure
Cooling water differential
MPa 0.1
pressure of inlet and outlet
17 Main motor
Main motor model Y315M-2
Main motor set One set
Nominal power of main motor kW 132
Power factor coefficient 1.15
114
Power supply 380
Main motor insulation grade F
Main motor protection grade IP54
Efficiency % 98
18 Unit noise dB(A) 76
19 Unit vibration m 6
20 Material and life
Main machine material Spheroidal cast iron
EN8M (High quality
Screw stem material and life h
carbon steel 45)
Bearing type and life h SKF more than 80000
Inlet air filter life h More than 8000
Oil-gas separator life h More than 8000
Oil filter life h More than 4000
21 Lubricating oil
Lubricating oil amount: l
Lubricating oil life: h 8000h
Lubricating oil consumption: l/h
Lubricating oil brand: CompAir special oil
22 Air filter filtering precision 3UM
Unit outline (length width
23 mm 2300*1500*1500
height)
24 Unit total weight kg 2393
Air compressor for

maintenance
1 Model D90
2 Type No oil screw air
compressor
3 Set 3
4 Outline dimension (length mm 2300*1500*1500
width height)
5 Installation type Installation with no
foundation
6 Rated air discharging amount Nm3/min 11.25
7 Rated air discharging pressure MPa(g) 0.8
115
8 Compressor rotating speed rpm 8560
9 Oil content in discharged air ppm 0
10 Dust particle in discharged air m 1
11 Air discharging temperature 45
12 Finished air pressure dew point 6

temperature
13 Compressed air outlet R3
specification
14 Unit noise (1m away from outer dB(A 76
surface of equipment) )
15 Unit weight kg 1923
16 Motor capacity kW 75
17 Voltage stage V 380
Front filter (air-liquid separator)
1 Type: SLAF-20HC
2 Rated air amount: Nm3/min 23.5
3 Rated working pressure: MPa 1.0
Equipment constant working
MPa 0.8
pressure:
Maximum working pressure: MPa 1.0
4 Maximum pressure loss: MPa 0.05
5 Maximum inlet air temperature: 45
6 Inlet air maximum oil content: ppm <10

7 Outlet air oil content: ppm 0.03
Highest environmental
8 <50
temperature:
9 Outlet air pressure dew point: -50
10 Rear cooler outlet temperature:
11 Cooling water
Cooling water quality
No impurity is seeable Common industrial water
requirement
Cooling water inlet water
38
temperature
Cooling water maximum flow m3/h 9.12
Cooling water inlet water
MPa 0.2~0.4
pressure
116
Inlet and outlet water
differential pressure of cooling MPa ~0.05
water
Using life of easily damaged Automatic water
12 h Above 8000 h
part: drainage machine
13 Motor
Type
Heater: 24
Power: kW
Compressor: 9.08
Rotating speed: rpm
Voltage V
Motor protection grade:
Insulation grade:
14 Using cooling agent R134a
Activated alumina,
15 Using sorbent
molecule screen
16 Sorbent regeneration time min ~155
17 Regeneration air consumption % <3
Air inlet and outlet interface
18 mm DN125
pipe diameter
19 Equipment dimension: m 270031003187
20 Equipment weight: kg 4950
Oil removing filter
1 Type MF0960
2 Rated treating air amount: Nm3/min 96
3 Separation principle Agglomeration filter
4 Rated working pressure MPa 1.0
5 Shell design pressure: MPa 1.0
Imported from
7 Filter element material: Over thin glass fibre
Germany
8 Filter element life: h 12000
Automatic blowdown valve
9 AD402-03
model
10 Maximum inlet air temperature 45
11 Filtering precision m 0.01

12 Residual oil content: ppm 0.03
117
13 mm DN100
pipe diameter
14 Equipment dimension m 4101305
Dust collecting filter
1 Model: SB0960
3
2 Rated dealing air amount: Nm /min 96
Direct holding up and
3 Separation principle
brown diffusion
6 Maximum pressure loss MPa 0.005
7 Filter element material Sinter bronze
can be cleaned
8 Filter element life h repeatedly for
generation
9 Maximum air inlet temperature 45
10 Filtering precision: m 1
11 mm DN100
pipe diameter
13 Equipment weight kg 78
Air-liquid separator
1 Model: GLS0800
3
2 Rated dealing air amount: Nm /min 80
Helix separation,
3 Separation principle removing foam by silk
screen
7 Water removing efficiency >98
8 Inner stuffing material

9 Stuffing life h
Automatic blowdown valve
10 AD402-03
model
11 Discharge space
118
12 Discharging time / time
13 mm DN125
pipe diameter
4.2 Overhaul Sort and Cycle Table 3-2

Sort Cycle Period
4.3 Overhaul Items
4.3.1 Air compressor overhaul items
4.3.1.1 Dismantle, check and clean filter element of air filter.
4.3.1.2 Check air storage tank and clean impurities inside oil-gas separator.
4.3.1.3 Clean and check air cooler and oil cooler pipe bundle.
4.3.1.4 Dismantle and check compressor main machine, check and replace parts such as gear,
screw stem and bearing.
4.3.1.5 Repair oil system, replace oil filter and clean oil level indicator.
4.3.1.6 Check whether all tubes are aged or not and check its sealing.
4.3.1.7 Check and analyze lubricating oil, it should be replaced if lubricating oil is not qualified.
4.3.1.8 Check and repair minimum pressure valve, air suction regulator, unloading solenoid valve,
breather valve, quick air discharging valve and blowdown valve; tightness test also should be
done.
4.3.1.9 Commission safety valve
4.3.1.10 Clean compressed air pipeline.
4.3.1.11 Blowdown for compressed air pipeline
4.3.1.12 Purge oil cooler and air cooler
4.3.1.13 Dismantle and check valves on pipeline and seal them again.
4.3.1.14 Replace oil separator element, oil filter element and air filter element.
4.3.2 Compressor minor overhaul
4.3.2.1 Analyze lubricating oil and replace it if it is not qualified.
4.3.2.2 Check sealing of all tube.
4.3.2.3 Replace oil filter and air filter.
4.3.2.4 Check whether safety valve is in normal service or not.
4.3.2.5 Check and clean cooler.
4.3.2.6 Seal sealing points with leakage again.
4.3.2.7 Clean compressed air pipeline.
4.3.2.8 Blowdown for compressed air pipeline.
4.4 Overhaul Process, Process Methods and Quality Standard
119
4.4.1 Preparation
4.4.1.1 According to operation condition and technical records of previous overhaul, confirm
abrasion and damage degree of all parts, make sure important overhaul technical plan and
technical measures arrangement.
4.4.1.2 Spare parts must be prepared for ensuring replacing parts in time during overhaul.
4.4.1.3 Prepare all kinds of special tools, common tools and measures for overhaul.
4.4.1.4 Check and test all lifting equipments and tools according to regulation.
4.4.1.5 Power supply, lamps and lanterns, illumination power supply should be arranged at site.
4.4.1.6 Equipment floor plane should be set during overhaul.
4.4.1.7 Prepare complete whole set of overhaul record tables and cards.
4.4.1.8 Clean site, arrange required parts, dismantling and special ground for repairing of main
4.4.1.9 Prepare sufficient oil storage barrel, crosstie and other things.
4.4.1.10 Issue thermal and mechanical work permit ticket.
4.4.2 Overhaul Process and Process Method
4.4.2.1 Pipeline dismantling
4.4.2.1.1 Dismantle all kinds of pipeline and detection points connecting with compressor.
4.4.2.1.2 Mark the position of pipeline for the convenience of reinstalling.
4.4.2.1.3 Interfaces of pipelines on equipment should be well sealed to avoid entering of
impurities.
4.4.2.2 Main machine overhaul
4.4.2.2.1 Repair only can be done after it is confirmed that power supply of motor is cut off and
thermal and mechanical work permit ticket has been issued.
4.4.2.2.2 Loosen connection bolts of coupling shell, mark connections of coupling and separate
them and check abrasion of coupling.
4.4.2.2.3 Loosen anchor bolts of motor and move motor away.
4.4.2.2.4 Discharge oil of gear box and main machine tank, dismantle all detection points.
4.4.2.2.5 Dismantle air suction regulator, unload solenoid valve and minimum pressure valve,
mark the position and do not mix them during reassembling.
4.4.2.2.6 Loosen bolts of cover end of main shaft, take off end cover.
4.4.2.2.7 Measure screw stem and clearances of all parts of bearing.
4.4.2.2.8 Loosen bearing pressing cover, bearing seat screw; take off pressing cover, bearing seat
in sequence; measure clearances of bearing and gear joggling parts; dismantle drive gear shaft.
4.4.2.2.9 Clean and check bearing and replace all the sealing rings.
4.4.2.2.10 Suspend main machine in advance with hoisting tools, loosen connection screw and
bolts connecting main machine and gear box, dismantle main machine and put it on crosstie or
ground with rubber.
4.4.2.2.11 Take out drive and driven screw stem and bearing sleeve.
4.4.2.2.12 Clean and check all parts, measure clearances of all parts.
4.4.2.2.13 Assemble parts to be replaced partially; check cooperation condition and prepare for
formal assembling.
4.4.2.2.14 Check all parts that are normal, clean it and there is no impurity in tank, reassemble it.
120
4.4.2.2.15 Assemble drive and driven screw stems according to corresponding position of joggling
gear groove, spread sealing glue on joint face, fill up sealing gasket, lift main machine, aim at
round column pin and tighten bolts.
4.4.2.2.16 Dismantling should be done with special tools during replacing bearing, hot pack may
be adopted during assembling; that is boil up bearing to 90~110 and then slip onto shaft.
4.4.2.2.17 Assemble main shaft according to corresponding position of joggling gear slot, install O
ring and reinstall bearing seat and pressing cover.
4.4.2.2.18 Reinstall subassemblies of single direction valve, unloading valve and oil shut-off valve.
4.4.2.2.19 Connect coupling and align motor.
4.4.2.2.20 Recover accessories of all detection points and fill oil for main machine head.
4.4.2.3 Air filter overhaul
4.4.2.3.1 Stop compressor and cut off power supply.
4.4.2.3.2 Loosen swing nuts on top of air inlet filter, take off cover and show filter element.
4.4.2.3.3 Dismantle filter element carefully, do not let dust drop into air inlet pipe.
4.4.2.3.4 Clean filter shell completely and clean all surfaces.
4.4.2.3.5 Purge old filter element or replace filter element, put filter element at right position.
4.4.2.3.6 Install top cover of air inlet filter and tighten swing nuts.
4.4.2.3.7 Reset air filter maintaining alarm.
4.4.2.4 Air storage tank and oil-gas separator overhaul
4.4.2.4.1 Stop air compressor and cut off power supply.
4.4.2.4.2 Loosen oil filling aperture and release pressure of air storage tank.
4.4.2.4.3 Dismantle short joint of upper cover of air storage tank and connection tie-in of upper
cover.
4.4.2.4.4 Loosen bolts and pin of upper cover and take off upper cover.
4.4.2.4.5 Take out oil-gas separator filter element and protect it to prevent impurity from entering
into it.
4.4.2.4.6 Clean and check oil-gas separator or replace it.
4.4.2.4.7 Clean joint face and replace sealing gasket.
4.4.2.4.8 Reinstall filter element, install sealing gasket and upper cover, tighten bolts.
4.4.2.4.9 Recover upper cover short joint and accessorial connection tie-in.
4.4.2.4.10 Dismantle minimum pressure valve; check piston, sealing ring and spring.
4.4.2.4.11 Dismantle safety valve subassemblies, check spring, valve seat and velve element that
should be complete and fine.
4.4.2.4.12 Test individual compressed air pipe, calibrate its pressure value.
4.4.3 Overhaul Quality Standard
4.4.3.1 Main Machine Quality Standard
4.4.3.1.1 Coupling should be complete and free from crackle or distortion.
4.4.3.1.2 Bearing inner and outer sleeve, ball bearing and bearing frame are complete and free
from corrosion, abrasion, exuviations and crackle.
4.4.3.1.3 Axial clearance of bearing complies with standard.
4.4.3.1.4 All type ring and gasket are strict and free from leakage, its specification is proper and
121
there is neither phenomenon of aging and stiffening nor pressing rupture. It is not allowed to be
used if its dimension is not proper.
4.4.3.1.5 It should be replaced if abrasion of gear exceeds 1/32/3 of original thickness, there is
no crackle or broken gear.
4.4.3.1.6 Gear contacts above 50% in gear length and above 40% in gear height.
4.4.3.1.7 Clearance of cooperation between gear and shaft is -0.01~+0.01mm, there is no
clearance at two sides of key and clearance on top is 0.200.4.mm.
4.4.3.1.8 It should be replaced if service time of screw stem exceeds 100, 000 hours.
4.4.3.1.9 Clearance between rotor and bush is 0.01dmm (d means outer diameter of screw stem).
4.4.3.1.10 heating temperature of bearing heating device should not exceed 120 and contact
between bearing and vessel is not allowed.
4.4.3.1.11 O ring on joint faces should be put well and screw tightening stress should be even.
4.4.3.2 Air filter quality standard
4.4.3.2.1 Filter element should be replaced if maintaining differential pressure of air filter exceeds
0.05bar.
4.4.3.2.2 Air filter element is clean and free from block, sieve has no dilapidation.
4.4.3.3 Air storage tank and oil-gas separator quality standard
4.4.3.3.1 It should be replaced if oil-gas separator differential pressure exceeds 0.5bar.
4.4.3.3.2 Oil-gas filter element is clean and free from block, sieve has no dilapidation.
4.4.3.3.3 Sealing of safety valve element and valve port is fine, spring is resilient and free from
distortion or breaking. There is no leakage in kerosene test, set value of safety valve is 8.5bar.
4.5.1 Safety
4.5.1.5 Fire must be avoided when cleaning or filling oil tank. Gasoline is prohibited to clean parts.
122
4.5.2 Health
4.5.3.3 Work completed, material is cleared up and site is clean.
123
Chapter Coal Powder Pipe and Its Accessories Maintenance Regulation
5.0 Applicable Scope and Quoted Material

This chapter is applicable for Indonesia Paiton 1660MW coal fired thermal power plant coal
powder pipe and its accessories maintenance and overhaul and to offer references and guides for
the maintenance personnel.
Quoted material: DL/T748.4 Thermal Power Plant Boiler Overhaul Guide Rules Part Four
Pulverizing System Overhaul
No. Name Specification Unit Qty Position Function Structure
1 Expansion 3.5MXP6006-J-2000 Piece 4 Lie on powder pipe of burner, protect pipeline
joint equipment and clean coal and hot stress to
make pipe expansion and shrinking free from
resistance
3.5XP6006-J-1500 Piece 4 Between mill outlet to coal powder distributor
2 Coal Cold air valve 4 Transport coal powder into burner

powder
pipeline
Regulable Hot air valve Regulate air mount of all coal powder pipeline
shrinking to be even
hole
3 Air valve Air regulation valve Set 4 Regulate coal powder temperature after
milling
Air ventilation valve Piece 1 Dry, take and transport coal powder
Sealing air valve Piece 1 Ensure coal powder air amount and air
pressure in mill
Hot air isolation valve Piece 1 Avoid hot air entering into mill during stopping
and starting mil
Pneumatic coal Piece 1 Sealing maze clearance and mill roller
powder isolation
valve
Manual coal powder Piece 1 Isolation hot air source for mill maintenance
isolation valve
4 Coal Fire fighting steam Piece 4 Positive pressure threatening working

powder valve personnel should be avoided during mill
isolation maintenance
valve
5 Fire Piece 4 Fire fighting
fighting
valve
Sort Cycle Period
124
5.3 Overhaul Items
5.3.1 Coal Powder Pipeline Major Overhaul Items
5.3.1.1. Check abrasion of coal powder chute completely.
5.3.1.2. Replace coal powder pipeline.
5.3.2 Coal Powder Pipeline Minor Overhaul Items
5.3.2.1 Check abrasion of coal powder pipeline.
5.3.2.2 Weld thinned parts due to abrasion by replacing.
5.4 Maintenance Process, Process Method and Quality Standard
5.4.1 Build up Reliable Scaffold
5.4.2 Coal Powder Pipeline Overhaul
5.4.2.1 Check abrasion of coal powder pipeline, mend seriously damaged part by replacing, whole
section of pipeline with serious distortion and mended area >1m2 should be replaced.
5.4.2.2 Mend by replacing should be done for coal powder pipeline, abrasion of which exceeds 1/3
of original thickness; it should be replaced if abrasion of mended plates of coal powder pipeline
exceeds 2/3; all welding points of pulverizing system pipeline should be smooth and free from
accumulated powder.
5.4.2.3 Sealing lining gasket can be spelled by several pieces and its juncture should be jointed in
tongue groove and strict. Every side of lining gasket should be plastered with water glass or white
lead oil, no lining gasket can be extended into pipeline to avoid adding resistance due to
accumulated coal powder.
5.4.2.4 Parallel misalignment of flanges of coal powder pipeline should be 3mm.
5.4.2.5 Cold-drawn should be done according to drawings during installation of wave expansion
joint, the direction of sealing lining ring welding in expansion joint and medium flow direction are
the same. Outlet side should not be welded.
5.4.2.6 When connecting coal powder pipeline and other mechanical shell, coal powder pipeline
generally does not bear weight of pipeline and displacement of mechanical device is not allowed.
5.4.2.7 Connection bolts hole of flanges should not be but by welding casually, bolts gasket should
not be more than 2 pieces and screw threads of bolts should protrude 2-3 rings.
5.4.2.8 No impurity is allowed in coal powder pipeline after overhaul; clean the temporary fixity and
welding slag.
5.4.2.9 Do the tightness test after coal powder pipeline overhaul.
5.4.3 Expansion Joint Maintenance
5.4.3.1 Check its appearance and whether it can flex freely or not in every overhaul, check its inner
abrasion, it should be replaced or welded by replacing when abrasion is serious.
5.4.3.2 Replace stuffing in every overhaul; check inner sleeve abrasion of expansion joint, replace
it if abrasion is serious to avoid leakage of coal powder.
5.4.4 Pipeline Supporting & Suspending Frame Maintenance
5.4.4.1 Completely check suspending and supporting frames in pulverizing system and clean the
defects, fixing bracket should be free from crackle, distortion or sliding. Sliding bracket should
move freely, spring of supporting and suspending frame should not be damaged and can flex
freely.
5.4.4.2 Spring compression of spring and suspending & supporting frame in coal powder pipeline
are proper; hoop of fixed bracket must be screwed down to avoid moving when heated, moving
bracket can move freely in expansion direction when it is heated.
125
5.4.5 Air Valve Overhaul
5.4.5.1 Check all the cold air valve, hot air valve, mixed air valve, isolation valve and all
motor-driven valve are straight and their pins are complete and fine.
5.4.5.2 Check that air valves shell should be free from abrasion and inner abrasion does not
exceed standard.
5.4.5.3 Check that all dampers of air valves and small shaft should be free from crackle and
distortion; it should be replaced if abrasion is serious.
5.4.5.4 Check that flange joint faces of air valve should be free from distortion and it should be
replaced if distortion is serious.
5.4.5.5 Check all flange gaskets of air valves, gland packing should be free from damage and air
leakage; otherwise, it should be replaced.
5.4.5.6 All manual valves, operation devices should be complete and indications are complete and
right, switch is agile and convenient.
5.4.5.7 All air valve can be opened or closed freely, strict and free from leakage, switch indication
should be consistent with actual openness, indications should be right.
5.4.5.8 All air valve, baffles, flashboard and valves can be opened or closed freely, leave
expansion clearance according to design drawings to avoid expansion.
5.4.5.9 All motor-driven operation devices should be with metal indication signs and installed with
switch limiter that can fully opened or closed.
5.5.1 Safety
5.5.1.5 Sufficient fire-fighting apparatus should be prepared at site.
5.5.2 Health
completed.
126
Chapter Boiler Mill Sealing Air Fan Maintenance Regulation
6.0 Applicable Range and Quoted Materials

This chapter is applicable for Indonesia Paiton 1660MW coal fired thermal power plant
MF9-25-12No12.5D sealing air fan (Shenyang Great Wall Air Fan Factory Co., Ltd.) maintenance
and overhaul and to offer references and guides for the maintenance personnel.
Quoted material: DL/T748.4 Thermal Power Plant Boiler Overhaul Guide Rules Part Four
Pulverizing System Overhaul
Pump and Air Fan Installation and Overhaul China Electric Power Press
Yang Shicheng Wang Xikui
Two centrifugal sealing air fans are equipped for each boiler pulverizing system in Indonesia
Paiton 1660MW subcritical unit coal fired power plant. The equipment is produced by Shenyang
Great Wall Air Fan Factory Co., Ltd. And its model is MF9-25-12No12.5D. Air fan inlet takes from
primary air fan inlet, pressurized cold air is supplied to mill after boosted in sealing air fan, and its
mainly used for sealing at mill roller, shell and lever. Equipment specification is as following:
No. Index Name Parameter Remark
1 Rated air amount 770m3/mint=35
2 Rated boosting pressure 9kp

3 Moment of inertia 210kg
4 Sealing air fan weight 19620 kg
5 Motor rated power 220
6 Motor rated rotating speed 1485r/ min
7 Motor rated voltage 380v
8 Motor weight 1400 kg
Sort Cycle Period
Minor overhaul 1 years 15 days
6.3 Overhaul Items
6.3.1 Check impeller abrasion completely. Replace impeller.
6.3.2 Check bearing abrasion and damage, replace bearing.
6.3.3 Repair cooling water system pipeline and valve. Clean equipment leakage.
6.3.4 Repair lubricating oil system, clean equipment leakage.
6.4 Overhaul Process, Process Method and Quality Standard
6.4.1 Dismantling Shell
6.4.1.1 Disassemble wheel-set cover and pins.
6.4.1.2 Disassemble bearing pressing cover and end cover, and put them at designated location.
6.4.1.3 Dismantle all bolts and positioning pin on air fan shell.
6.4.1.4 Lift shell to designated location with traveling crane.
127
6.4.1.5 Lift rotor to designated location with traveling crane. Rotor should be in level during lifting
process.
6.4.2 Disassembling Bearing
6.4.2.1 Take off bearing sleeve with special cart puller.
6.4.2.2 Disassemble lock nuts and stop gaskets of bearing.
6.4.2.3 Take off bearing with cart puller; heat up bearing before taking it if it is necessary. Force
bearing part of cart puller should be on inner ring of bearing.
6.4.3 Repair Bearing
6.4.3.1 Clean bearing with kerosene and wipe up it with cloth.
6.4.3.2 Check rolling part of bearing which surface should be free from crackles, blow spot and
corrosion.
6.4.3.3 Check isolation ring of bearing that should be free from looseness.
6.4.3.4 Check inner & outer ring and rolling trace of the bearing, which should be crackle,
corrosion and scar.
6.4.3.5 Turn the bearing manually and watch its turning. Bearing should slow down gradually and
be free from reversal running.
6.4.3.6 Measure clearance of bearing and record it well.
6.4.4 Reinstalling Bearing
6.4.4.1 Bearing should be reinstalled after checking it to be qualified; if it is new bearing, 4.14.6
should be repeated, and then reinstall it.
6.4.4.2 Check bearing neck, it should be grinded clean with sand paper if there is burr.
6.4.4.3 Measure inner diameter of bearing neck and bearing and record it well. Cooperation
tightening stress of bearing should be +0.020.05mm.
6.4.4.4 Heat up bearing with oil. Oil temperature should be about 80 and no lea than 120;
heating up time is 3060 minutes.
6.4.4.5 Slip heated bearing into bearing neck immediately and knock it evenly with copper stick.
Clearance between bearing and bearing shoulder should be zero.
6.4.4.6 Install stop gasket and lock nut, cool down bearing naturally.
6.4.4.7 Reinstall bearing sleeve, it can be heated up slightly if it is difficult to install.
6.4.5 Repair Main Shaft and Impeller
6.4.5.1 Check impeller and main shaft: main shaft should be free from abrasion, corrosion or
bending. Impeller should be free from abrasion and thickness should be no less than 1.5mm.
6.4.6 Repair Labyrinth Sealing Ring
6.4.6.1 Check labyrinth gear surface. Maze is free from distortion or breaking.
6.4.6.2 Check abrasion of labyrinth, it should be replaced if abrasion of maze teeth exceeds 2/3.
6.4.7 Reinstall Parts of Air Fan
6.4.7.1 Clean joint faces of upper and lower shell.
6.4.7.2 Lift rotor together with impeller and low down into lower shell stably, regulate the axial and
radial clearances between sealing ring and shaft and impeller. Rotor level degree 0.20mm/m,
axial clearance of sealing ring and impeller is 1.53mm and radial clearance between sealing ring
and shaft is 0.52.0mm; If these clearances can not be got, sealing ring should be taken out for
128
scarping.
6.4.7.3 Regulate top, expansion and axial clearances of front and rear bearing.
6.4.7.4 Proper molybdenum disulfide should be filled in bearing housing, reinstall bearing
transparent cover, end cover and upper cover.
6.4.7.5 Spread sealing glue and 1mm asbestos thread on joint surface of lower shell, put upper
shell on lower one slightly and position them with pin, and then tighten upper and lower shell with
M16 bolts.
6.4.7.6 Align wheel-set. Clearance of two couplings is 46mm. Axial and radial windage of two
couplings is less than or equals to 0.04mm; generally, air fans clearance is 0.03mm lower than
motors.
6.4.7.7 Test motor to check its running direction.
6.4.7.8 Reinstall coupling pin and protection cover. Confirm that power supply of motor ahs been
cut off before reinstalling.
6.4.7.9 Trial run of air fan. After normal major overhaul, trial run time of air fan should be no less
than 8 hours and no less than 1 hour for daily maintaining. During operation of front and rear
running X, Y and Z swing should be 0.10mm. Front and rear bearing temperatures should not
exceed 80 at most. Air fan inside and bearing are free from noise.
6.5.1 Safety
6.5.2 Health
completed.
129
Chapter Primary Air Fan, Forced Draft Fan and Introduced Draft Fan Maintenance
Regulation

This chapter is applicable for Indonesia Paiton 1660MW coal fired thermal power plant
primary air fan, forced draft fan (Shanghai Blower Factory Co., Ltd.) and introduced draft fan
(Chengdu Machinery Co., Ltd.) maintenance and overhaul and to offer references and guides for
the maintenance personnel.
Quoted material:
Primary Air Fan Installation Manual Engineering Co., Ltd.
Introduced Draft Fan Installation Manual Engineering Co., Ltd.
Primary Air Fan Operation & Maintenance Manual Engineering Co., Ltd.
Introduced Draft Fan Operation & Maintenance Manual Engineering Co., Ltd.
Pump and Air Fan Installation and Maintenance China Electric Power Press Yang
Shicheng Wang Xikui
1.1 Gas-air System Brief Introduction and Main Equipment Parameters
1.1.1 Gas-air System Brief Introduction
Gas-air system mainly consists of forced draft fan (FDF), introduced draft fan (IDF), primary
air fan (PAF), gas duct, primary and secondary air ducts, dampers and air heater. Cold air system
in this boiler adopts two FAF26.6-13-1 type single stage, drive impeller, regulable and axial flow
FDF, two PAF20-12.5-2 type double stage, drive impeller, regulable and axial flow PAF, which are
produced by Shanghai Blower Factory Co., Ltd and are running in parallel. In order to increase
primary and secondary air inlet temperature of air preheater, two SAH--3DZ2790X4340X450
type primary air and SAH--3DZ5410X8300X450 type secondary air heaters are respectively
installed at inlets of primary air and secondary air. Primary air enters into primary air
compartmentation bunker of airpreheater for heating and then enters into mill; a part of coal air
before entering into air preheater enters into mill inlet through bypass and mixes with hot primary
air, which would work as mill outlet temperature regulation air. Secondary air enters into secondary
air compartmentation of air preheater and enters into big air box after heating up and works as
combustion-supporting air. Gas discharging system adopts two AN40e6(13) stationary impeller,
regulable and axial flow air fans that are produced by Chengdu Machinery Factory Co., Ltd and
are running in parallel. Gas is discharged from boiler tail to air through air preheater, ESP and FDF.
1.1.2 Axial Flow Air Fan and Oil Station Main Performance Parameter
1.1.2.1 IDF main performance parameter:
Table 1-1
No. Name Unit Model parameter
1 Air fan type AN40e6(13)
2 Air fan regulation device model Static impeller, regulable
3 Impeller diameter mm 4000
4 Shaft material 35CrMo
5 Hub material Q345
6 Impeller material WH60Anti-abrasion
7 Impeller using life h 50000 hours
130
8 Impeller stages stage 1
9 Blade number of each stage piece 13
10 Specific rotating number 107
11 Static impeller regulable range Degree -7530
12 Rotor weight kg 7000
13 Rotor moment of inertia kg.m2 7350 kg m2
14 First critical rotating speed of air fan r/min 780r/min
15 Inlet air box material/wall thickness mm Q235/8
16 Shell material/wall thickness mm Q235/22
Pressure expander material/wall Q235/8
17 mm
thickness
18 Air fan bearing type Roller bearing
19 Bearing lubrication type Grease lubrication
20 Bearing cooling type Air cooling
21 Cooling air fan type/quantity G9-195A/2
22 Cooling air fan power KW 7.5
Cooling air amount and pressure 16103166m/h
26
56975232Pa
Air fan rotating direction (from motor Anticlockwise
27
side)
28 Motor power kW 4500
29 Air fan total weight kg 75000
Maximum lifting weight/height during 12000/11 (from zero plane of
30 kg/mm
installation foundation)
Maximum lifting weight/height during 7000/11 (from zero plane of
31 kg/mm
maintenance foundation)
Air fan shell inner diameter and 5
32 mm
impeller outer diameter clearance
1.1.2.2 IDF motor oil station main performance parameter:
Table 1-2
No. Name Unit Model parameter
1 Flow L/min
2 Pressure Mpa
3 Oil quality brand
4 Oil tank material/volume /m3
5 Oil filter filtering precision m
6 Oil cooler water pressure Mpa
7 Oil cooler type
131
8 Oil pump type
9 Oil pump quantity Set
10 Oil pump rotating speed r/min
11 Oil pump power Kw
1.1.2.3 FDF main performance parameter:
Table 1-3
No. Name Unit Model and parameter
1 Air fan model FAF26.613.31
2 Air fan regulation device model 100Nm

4 Bearing material 42CrMo-5
5 Hub material 15MnV
6 Blade material HF-1
7 Impeller stages stage 1
8 Blade number per stage Piece 16
9 Impeller regulation range Degree -2015
10 Hydraulic cylinder diameter and journey mm/mm 366/H100
2
12 Rotor moment of inertia kgm 468
13 First critical rotating speed of air fan r/min 1281
14 Inlet air box material/wall thickness mm Q235A/5
15 Shell material/wall thickness mm Q235A/12
16 Pressure expander material/wall mm Q235A/5
thickness
17 Air fan bearing model Roller bearing
18 Bearing lubricating mode Watery oil
19 Bearing cooling type Oil pool + forceful oil circulating
20 Motor power kW 1600
21 Air fan rotating direction (from motor Anticlockwise
side )
23 Maximum lifting weight/height during kg 15000shell+ rectifying guide
installation
mm flow ring + rotor sleeve
24 Maximum lifting weight during kg 6000rotor
maintenance
mm
6.5 M
25 Clearance between air fan shell inner
mm 2.7+0.5
diameter and impeller outer diameter
1.1.2.4 FDF lubricating oil station main performance parameter:
Table 1-4
No. Name Unit Model and parameter
132
1 Flow L/min 25
2 Pressure MPa 3.53
3 Oil quality brand N68
4 Oil tank material Q235A
3
5 Oil tank volume m 0.4
6 Oil filter filtering precision m 25
7 Oil cooler cooling water amount t/h 3
Oil cooler cooling water pressure
8 MPa 0.60.1
9 Oil cooler type Pipe array type
10 Oil pump type Gear
11 Oil pump quantity set 2
12 Oil pump rotating speed r/min 1450
13 Oil pump power kW 5.5
14 Oil tank electric heater quantity set 1
15 Oil tank electric power KW 2.5
1.1.2.5 PAF main performance parameter:
No. Item Unit Value
1 Air fan model PAF20-12.5-2
2 Air fan regulation device model 100Nm
4 Bearing material 42CrMo-5
5 Hub material 15MnV
6 Blade material HF-1
7 Impeller stages Stage 1
8 Blade number per stage Piece 24
9 Impeller regulation range Degree -25+20
10 Specific rotating numer

Hydraulic cylinder diameter and 366/50
11 mm/mm
journey
2
13 Rotor moment of inertia kg.m 2832
First critical rotating speed of air 1911
14 r/min
fan
15 Inlet air box material/wall thickness /mm Q235/6
16 Shell material/wall thickness /mm Q235/ thickness is no less than 12
Pressure expander material/wall Q235A/5
17 /mm
thickness
18 Air fan bearing model Roller bearing
133
No. Item Unit Value
19 Bearing lubricating mode Watery oil
20 Bearing cooling type Oil pool + forceful oil circulating
21 Bearing pad cooling water amount t/h
Air fan rotating direction (from anticlockwise
22
motor side)
<150
23 Silencer resistance TB Pa
24 Silencer weight kg 10370

Maximum lifting weight during 15000shell+ rectifying guide flow
installation
26 kg ring + rotor sleeve
3
Maximum lifting height during 4500 rotor sleeve
27 installation m
3
Table 1-5
No. Item Unit Value
1 Motor type Asynchronous squirrel cage type
2 Motor model YKK710-4
3 Rated power kW 3150
4 Rated voltage V 6000
5 Rated current A 356
6 Rated rotating speed r/min 1490
7 Protection grade IP55
8 Insulation grade F
9 Cooling type IC611
10 Connection mode Y
11 Bearing type Sliding
12 Bearing lubrication type Forceful lubrication
13 Bearing cooling type Oil cooling
2
15 Moment of inertia kg.m 190
16 Motor total weight kg 16900
1.1.2.6 PAF lubricating oil station main performance parameter:
Table 1-6
No. Item Unit Value
1 Flow l/min 25
2 Pressure MPa 3.5
134
No. Item Unit Value
3 Oil quality brand N68
4 Oil tank material Q235A
3
5 Oil tank volume m 0.25
6 Oil filter filtering precision 25
Oil cooler cooling water
7 t/h 2.25
amount
Oil cooler cooling water
8 MPa 0.3~0.6
pressure
9 Oil cooler type Pipe type
10 Oil pump type Gear pump
11 Oil pump quantity set 2
12 Oil pump rotating speed r/min 1470
13 Oil pump power 2.2
Oil tank electric heater
14 set 2
quantity
15 Oil tank electric power kW 2.2
1.2 Axial Flow Air Fan Overhaul Sort, Cycle and Period
Sort Cycle Period
1.3 Axial Flow Air Fan Overhaul Items
1.3.1 Major Overhaul Items
1.3.1.1 IDF Overhaul Standard Items
1.3.1.1.1 Check abrasion of shell, lining plate, impeller, blade and guide impeller and record it well,
replace them if it is necessary.
1.3.1.1.2 Check inlet & outlet regulation damper and transmission device, fill lubrication grease
into damper shaft foundation.
1.3.1.1.3 Check roller bearing and repair or replace it according actual condition.
1.3.1.1.4 Dismantle and check lubricating oil pump, replace gland sealing and replace oil pump
when abrasion is serious.
1.3.1.1.5 Check all valves in oil system and clean leakage points.
1.3.1.1.6 Clean lubrication oil tank and replace it according to actual condition.
1.3.1.1.7 Dismantle and clean oil cooler and do the pressure test.
1.3.1.1.8 Check expansion joint whether it has air leakage or not.
1.3.1.1.9 Check cooling air fan of bearing and replace it according to actual condition.
1.3.1.1.10 Check cooling water system.
1.3.1.1.11 Check sliding bearing of motor and grind the shaft pad surface according to actual
condition.
1.3.1.2 IDF Overhaul Non-standard Items
135
1.3.1.2.1 Replace whole air fan impeller, lining plate, impeller, damper and shell.
1.3.1.2.2 Replace main shaft part.
1.3.1.2.3 Replace bedplate and build foundation again.
1.3.1.3 FDF Overhaul Standard Items
1.3.1.3.1 Check abrasion of shell, lining plate, impeller and outlet guide blade, record it well and
replace it if it is necessary.
1.3.1.3.2 Calibrate inlet drive impeller, outlet damper openness.
1.3.1.3.3 Check outlet regulation damper and transmission device, fill up lubrication grease into
gear box of damper bearing and transmission device.
1.3.1.3.4 Measure clearance between impeller top and shell.
1.3.1.3.5 Check control head, hydraulic cylinder, bearing box and hub.
1.3.1.3.6 Check expansion joint whether it has air leakage or not.
1.3.1.3.7 Dismantle and check oil pump at hydraulic oil station, replace oil sealing and replace oil
pump if abrasion is serious.
1.3.1.3.9 Clean oil tank in hydraulic oil station, replace lubricating oil according to actual condition.
1.3.1.3.10 Dismantle and clean oil cooler in hydraulic oil station do the pressure test.
1.3.1.3.11 Check impeller root and hub with destructive inspection
1.3.1.3.12 Check inlet silencer and air duct welding points.
1.3.1.4 FDF Overhaul Non-standard Items
1.3.1.4.4 Dismantle and repair bearing box, hub and control head hydraulic cylinder.
1.3.1.5 PAF Overhaul Standard Items
1.3.1.5.1 Check abrasion of shell, lining plate, impeller and outlet guide blade, record it well and
replace it if it is necessary.
1.3.1.5.2 Calibrate inlet drive impeller, outlet damper openness.
1.3.1.5.3 Check outlet regulation damper and transmission device, fill up lubrication grease into
gear box of damper bearing and transmission device.
1.3.1.5.4 Check control head, hydraulic cylinder, bearing box and hub.
1.3.1.5.5 Dismantle and check oil pump at hydraulic oil station, replace oil sealing and replace oil
pump if abrasion is serious.
1.3.1.5.7 Clean oil tank and lubricating oil station of motor, replace lubricating oil according to
actual condition.
1.3.1.5.8 Dismantle and clean oil cooler in hydraulic oil station, do the pressure tests.
1.3.1.5.9 Check impeller root and hub with destructive inspection.
1.3.1.5.10 Check inlet silencer and air duct welding points.
1.3.1.5.11 Check expansion joint whether it has air leakage or not
1.3.1.5.12 Check clearance between impeller top and shell
136
1.3.1.5.14 Check motor sliding bearing and grind bearing pad surface according to actual
condition.
1.3.1.6 PAF Overhaul Non-standard Items
1.3.1.6.4 Dismantle and repair bearing box, hub and control head hydraulic cylinder.
1.3.2 Minor Overhaul Items
1.3.2.1 IDF Minor Overhaul Standard Items
1.3.2.1.1 Clean defects during equipment running, check abnormal parts during operation and
replace it if it is necessary, clean all the leakage points.
1.3.2.1.2 Clean and check bearing box, impellers, guide blades, gas duct and dampers of air fans;
measure and check abrasion of impellers, blades, supporters and gas & air ducts, do anti-abrasion
treatment or replace it if necessary.
1.3.2.1.3 Check and clean oil system of equipment, check elastomer and gland sealing of oil pump,
clean oil cooler.
1.3.2.1.4 Analyze lubricating oil quality in lubricating oil station of the motor, replace it if necessary.
1.3.2.1.5 Make all signs and marks for the equipment; paint on equipment is complete and free
from dropping.
1.3.2.1.7 Check inlet stationary impeller and outlet damper openness.
1.3.2.2 FDF Minor Overhaul Standard Items
clean oil cooler.
from dropping.
1.3.2.3 PAF Minor Overhaul Standard Items
clean oil cooler.
137
from dropping.
1.4 Axial Flow Air Fan Overhaul Process, Process and Quality Standard
1.4.1 Preparation
1.4.1.1 Confirm important maintenance technical plan and technical measures arrangement and
abrasion or damage degree of all parts according to running condition and technical records of
previous maintenance.
1.4.1.2 Spare parts should be prepared in advance to ensure parts can be changed timely in
maintenance.
1.4.1.3 Prepare all kinds of maintenance special tools, general tools and measures.
1.4.1.4 All lifting devices, tools should be tested and checked according to regulation.
1.4.1.5 Construction power supply, lamps and lanterns and illumination power supply should be
arranged at construction site, scaffold should be built at the same time with maintenance of
cooling water wall.
1.4.1.6 Floor plan of equipment parts should be set during maintenance.
1.4.1.7 A complete set of recording tables and cards should be prepared.
1.4.1.8 Clean site, arrange special location for arranging required parts, dismantling and main
1.4.1.9 Prepare sufficient crosstie, wooden plates and other things.
1.4.1.10 Mechanical work permit ticket should be issued.
1.4.2 IDF Overhaul Process and Process Method
1.4.2.1 Pipeline Disassembling
1.4.2.1.1 Dismantle all pipelines and detection points connecting to air fan, corresponding position
on shell should be marked.
1.4.2.1.2 Positions of all pipelines should be marked for the convenience of arranging temporary
warning signs.
1.4.2.1.3 Seal the pipeline interfaces on equipments to avoid entering of impurities.
1.4.2.2 Static State Fittings Disassembling
1.4.2.2.1 Dismantle sound insulation around flying rings and air fan shell.
1.4.2.2.2 Dismantle flexible connection between diffuser and pressure pipeline, loosen bolts
among impeller shell, diffuser and shell inlet.
1.4.2.2.3 Clean moving trace, check transportation trace.
1.4.2.2.4 Push diffuser into pressure pipeline along axial direction and fix it.
1.4.2.2.5 Put blades at close position; demount connection bolts and pins on plane of shell.
1.4.2.2.6 Suspend upper section of shell in the air, lift shell vertically until shell would not contact
with blade when it is moving. Move out shell transversely and put it on wooden plate.
1.4.2.2.7 Clean and check all parts, check abrasion of shell and replace it according to actual
condition if necessary.
1.4.2.3 Impeller Disassembling
1.4.2.3.1 Dismantle the part of inlet guide blade device element near impeller end.
1.4.2.3.2 Support middle shaft connecting to half coupling, loosen half coupling.
138
1.4.2.3.3 Dismantle short shaft pipe of middle connection shaft, heat up coupling evenly and then
demount coupling.
1.4.2.3.4 Suspend 4-5 blades in about 45 area of upper section of impeller with steel rope to
stabilize impeller.
1.4.2.3.5 Dismantle pressing plate bolts of front half section of impeller, then impeller can be
moved in axial direction, move impeller in axial direction forwards to avoid cold air cover until it can
be lifted freely.
1.4.2.4 Disassemble and Check Inlet Guide Blade
1.4.2.4.1 Dismantle moving joints from inlet guide blade regulation device air box and current
collector aix box upper section of current collector.
1.4.2.4.2 Dismantle bolts on horizontal connection surface of inlet current collector, dismantle bolts
on vertical connection surface of upper section of air box.
1.4.2.4.3 Dismantle inlet guide blade regulation device element at vertical connection and put it on
bearing.
1.4.2.4.4 Dismantle bearing protection sleeve and loosen lever.
1.4.2.4.5 Draw out element towards inlet elbow.
1.4.2.4.6 Dismantle tightening bolts and pull off execution lever from guide shaft.
1.4.2.4.7 Lift bearing seat for the convenience of demounting clip ring of inner bearing, and
dismantle it off.
1.4.2.4.8 Draw out guide blade towards inner direction.
1.4.2.5 Bearing Group Disassembling
1.4.2.5.1 Dismantle front and rear cooling air cover, loosen all pipeline and measuring lines, mark
them for the convenience of reinstalling.
1.4.2.5.2 Support the bearing group, dismantle bolts connecting shell element, lift shell away from
bearing group and then put in on crosstie stably.
1.4.2.6 Main Bearing Disassembling
1.4.2.6.1 Wipe up bearing group with cotton yarn and dismantle end covers at two sides of beaing.
1.4.2.6.2 Dismantle lining ring with tools; if the tension stress is too big, oxygen can be used for
firing but the temperature should not be too high.
1.4.2.6.3 Dismantle clip ring with special tools.
1.4.2.6.4 Dismantle lower cover and pressing cover.
1.4.2.6.5 Draw out bearing, bearing inner ring and isolation ring together from bearing box as per
air flow direction.
1.4.2.6.6 Dismantle outer ring with hydraulic tools.
1.4.2.6.7 Clean all parts of bearing and replace it if necessary.
1.4.2.7 Main Bearing Assembling
1.4.2.7.1 Before installation, measure dimension of inner and outer rings, measure clearance
between round and roller bearing with feeler gauge; move outer ring from inner ring for the
convenience of installing scale plate to measure bearing clearance.
1.4.2.7.2 Heat up main shaft and closing ring to 800C and 1000C in maximum. Oil bath or induction
heating is adopted for heating and sufficient oil with flashpoint above 2500C is used for heating.
1.4.2.7.3 Install closing ring and roller bearing on bearing end, abut part against contacting surface
until temperature is cooled down to make cooperation between closing ring and shaft shoulder
proper, check radial clearance.
139
1.4.2.7.4 Install thrust bearing on shaft from reversal direction and press it onto closing ring slightly
until it is cooled down.
1.4.2.7.5 After installing bearing onto main shaft, measure round and roller bearing clearance with
feeler gauge, move outer ring from inner ring for the convenience of installing scale plate to
measure bearing clearance.
1.4.2.7.6 Check axial clearance of roller bearing, install accessories on oil pipeline, cooling air
cover and bearing box.
1.4.2.8 Coupling Installation
1.4.2.8.1 Heat up wheel-set evenly and install it on main shaft.
1.4.2.8.2 Connect middle bearing of wheel-set well, align with micrometer and then tighten
coupling bolts and install its cover.
1.4.2.9 Static State Fittings Assembling
1.4.2.9.1 Install upper section of air fan shell and spread grease on joint face.
1.4.2.9.2 Install pulling fork of inner shell of diffuser onto rotating gland sealing and connect it to
regulation arm.
1.4.2.9.3 Connect servo motor and regulation arm, install sealing air pipes, install maintenance
door on inner shell of diffuser.
1.4.2.10 Repair Motor Bearing Pad
1.4.2.10.1 Discharge lubricating oil completely from bearing pad seat.
1.4.2.10.2 Contact with I & C personnel to dismantle I & C elements.
1.4.2.10.3 Dismantle upper cover of bearing pad and measure clearance of upper cover and
bearing pad and record it.
1.4.2.10.4 Demount bearing pad and dismantle oil-splash ring, measure clearance between
bearing pad and top of bearing and clearance between two sides, record original values well.
1.4.2.10.5 Prop up main bearing and take off bearing pads.
1.4.2.10.6 Check whether shaft surface is smooth or not, polish it with natural whetstone if there is
burr or indention.
1.4.2.10.7 Spread red lead powder on bearing pad after grinding it as per requirements.
1.4.2.10.8 Put bearing pad into bearing seat, low down main bearing, turn main bearing in air fan
rotating direction to grind bearing pad.
1.4.2.10.9 Take off bearing pad according to process 5 to check contacting condition of pad
surface; if it does not comply with standard, process 5, 6 and 7 should be done until bearing pad
grinding is qualified.
1.4.2.10.10 clean bearing seat, bearing pad and main shaft, file burr on edge of bearing pad.
1.4.2.10.12 Reinstall bearing pad.
1.4.2.11 Repair Motor Oil Station
1.4.2.11.1 Dismantle and check elements of oil pump and filter, it should be replace if necessary.
1.4.2.11.2 Check and clean oil cooler and have hydraulic test.
1.4.2.11.3 Clean oil tank, clean all pipe connections and leakage of valves.
1.4.2.11.4 Analyze oil and fill to normal level with qualified lubricating oil.
1.4.3 IDF Overhaul Quality Standard
1.4.3.1 Preparation
140
1.4.3.1.1 Original records must be complete and right before overhaul.
1.4.3.1.2 Lifting tools, safety tools must comply with related regulations.
1.4.3.1.3 Check the related dimensions of all spare parts as per drawings, necessary destructive
inspection should be done and record it well.
1.4.3.2 Air Fan Overhaul Quality Standard
1.4.3.2.1 Blade should be complete and footstalk tightening bolts are free from looseness.
1.4.3.2.2 Stationary blade regulation actuator works normally, indication is right and in consistent
with blade actual openness.
1.4.3.2.3 Air inlet room, shell, pressure expanding section and expansion should be complete and
free from welding crack and fatigue crackle; bolts are free from looseness.
1.4.3.2.4 Middle shaft, coupling and bearing box foundation should be complete; bolts are free
from looseness, distortion and crack.
1.4.3.2.5 Oil system pipeline is free from leakage.
1.4.3.3 Coupling Assembling Quality Standard
1.4.3.3.1 Connection bolts should be free from abrasion; bending and screw threads should be
complete.
1.4.3.3.2 Spring leaf should be free from distortion and fatigue crack.
1.4.3.3.3 Heating up temperature should not exceed 150 when installing coupling in hot state
and flame should not heat up spring leaf directly.
1.4.3.3.4 Eccentricity of coupling should be no higher than 0.10mm, motor anchor gasket should
not exceed three pieces and anchor bolts force are even.
1.4.3.3.5 Coupling safety cover is fixed firmly and free from friction.
1.4.3.4 Impeller Overhaul Quality Standard
1.4.3.4.1 Radial clearance of shell and impeller is 5mm.
1.4.3.4.2 Abrasion between blade and welding line should not exceed 1/4, otherwise it should be
repaired or replaced.
1.4.3.4.3 Guide blade abrasion should not exceed 1/3, otherwise it should be repaired or replaced.
1.4.3.4.4 Impeller is proved to be free from crack, slag inclusion or aperture through destructive
inspection.
1.4.3.5 Damper Overhaul Quality Standard
1.4.3.5.1 Out & inlet baffles abrasion should not exceed 1/5, and they can turn freely.
1.4.3.5.2 Cooperation clearance of outlet & inlet damper bearing and bearing sleeve should not
exceed 0.30mm.
1.4.3.5.3 Inlet stationary blade regulation plate, positioning wheel and winch lever should turn
freely.
1.4.3.5.4 Inlet stationary blade can be regulated continuously within -75 +30 and free from
block, and all dampers can turn synchronously.
1.4.3.5.5 Outlet damper can be fully opened or closed and its operation is agile.
1.4.3.6 Bearing Box Overhaul Quality Standard
1.4.3.6.1 Bearing inner & outer ring should be free from rust, blow spot, scar, double skin, color
changing and crack. Clearance of new bearing is 0.15-0.20mm and old bearing should no higher
than 0.35mm.
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1.4.3.6.2 Ensure that frame abrasion should not exceed 1/3, axial abrasion scar do not exceed
0.05-0.1mm, ellipse do not exceed 0.03mm and cone degree so not exceed 0.03mm.
1.4.3.6.3 Main shaft bending degree is no higher than 0.05mm/m and plane error is no bigger than
0.02mm.
1.4.3.6.4 Radial cooperation clearance of bearing outer ring and bearing box is 0.0525mm,
contacting angle is 120, contacting points at two sides should form a gradually transitional trace,
sizes of contacting points should be the same of 1-2 points per square meter. The points are
evenly distributed.
1.4.3.6.5 Radial cooperation clearance of bearing outer ring and bearing box is 0.10-0.20mm and
axial clearance of bearing outer ring is 0.20-1.00mm.
1.4.3.6.6 Oil filling mouth should face to bearing directly.
1.4.3.6.7 Fire wielding or argon arc welding should be done for rendering before welding oil filling
and discharging pipes.
1.4.3.6.8 All tie-in, joint faces and valves of oil system should be free from oil leakage.
1.4.3.7 Motor Lubricating Oil Overhaul Quality Standard
1.4.3.7.1 Clean oil tank that should be free from impurities.
1.4.3.7.2 Clean oil filter element, discharge residual oil completely from filter.
1.4.3.7.3 Clean oil cooler shell and inner pipe walls, do the hydraulic test.
1.4.3.7.4 Fill oil to normal level.
1.4.3.7.5 Oil pump outlet pressure should not be lower than 0.20Mpa, motor bearing pad supplying
oil pressure should be lower than 0.16Mpa.
1.4.3.8 Motor Bearing Pad Overhaul Quality Standard
1.4.3.8.1 Cooperation tightening stress of bearing upper cover and upper bearing pad should be
0.02 0.04mm.
1.4.3.8.2 Alloy tile surface should be glabrous and show silvery white and free from yellow blow
spot, impurity, air hole, flaking, crack and indention.
1.4.3.8.3 Contact angle of bearing and bearing bushing is 65 90 and contacting points on
contacting edge should be with transitional trace. In permit contacting range, its contacting points
should be the same in size and evenly distributed in axial direction, check with printing color that it
should be 23 points/m2.
1.4.3.8.4 Clearance at top of bearing bush should be 1/1000 2/1000 of bearing diameter
(bigger value is applicable for smaller value), that is 0.2mm 0.4mm, if bearing bush clearance
exceeds this range, milling and digging method should be adopted for processing joint face of
bearing bush.
1.4.3.8.5 For the clearances at two sides of new bearing bush, insert 15mm 20mm along
bearing with 0.15mm feeler gauge; and insert 15mm 20mm with 0.03mm feeler gauge for old
bearing bush.
1.4.3.8.6 Bearing bush should not turn on bearing seat and contacting points on joint face of
bearing bush should be evenly distributed and no less than 1 point/ m2; filling up is not allowed
generally.
1.4.3.8.7 Contacting points of bearing bush end surface and bearing shoulder should be evenly
distributed and no less than 2 points/ m2, its bearing bush round angle should not contact with
round angle of bearing shoulder.
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1.4.3.8.8 Oil-splash ring should be round and its ring thickness should be even, its surface should
be smooth, its interface should be firm, oil ring in grove has no block and keep turning in even
speed with the bearing.
1.4.3.9 Air Fan Trial Run
1.4.3.9.1 After 8 hours trial run, air fan bearing temperature should be no higher than 80 and
bearing vibration value should be no higher 0.03mm.
1.4.3.9.2 Static part and turning part should be free from block, impact or friction; bearing sound
should be normal.
1.4.3.9.3 All flanges, manholes and oil sealing should be strict and free from leakage; through-flow
part and blade have no impact and noise; there is no leakage of smoke, ash, oil and water;
damper switch should be agile and indication should be right.
1.4.3.10 Motor Lubricating Oil Trial Run
1.4.3.10.1 Oil system and cooling water pipe should be smooth and oil level is normal.
1.4.3.10.2 Lubricating oil pressure complies with standard.
1.4.3.10.3 Oil pump rotating is stable and free from noise.
1.4.3.10.4 All tie-in of pipes and valves are free from oil leakage.
1.4.3.10.5 All oil level indications and signs at oil station are complete and right.
1.4.4 FDF Overhaul Process and Process Method
1.4.4.1.1 Dismantle all pipelines and detection points connecting to air fan, corresponding position
1.4.4.1.2 Positions of all pipelines should be marked for the convenience of arranging temporary
warning signs.
1.4.4.3 Rotor Assembly Dismantling
1.4.4.3.1 Disassemble blade regulation device, dismantle and separate regulation bearing from
indication bearing.
1.4.4.3.2 Separate security flat steel of main bearing box oil pipeline and main bearing box,
hydraulic pressure device oil pipeline and impeller regulation device and preventing hydraulic
pressure control head restoration from hydraulic control head of hydraulic regulation device.
1.4.4.3.3 Loosen connection bolts of half coupling of middle bearing and at air fan side.
1.4.4.3.4 Support middle bearing in air inlet box, and spring leaf coupling at compression motor
side.
1.4.4.3.5 Loosen connection bolts between main bearing box flange and supporting ring of lower
section of air fan shell.
1.4.4.3.6 Lift rotor assembly and put it into special bracket.
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1.4.4.3.7 Keep it stable in level when lifting the rotor, and lift it upwards vertically from shell lower
section.
1.4.4.3.8 When rotor is laid on special bracket, its blade should not contact with ground or bracket.
1.4.4.4 Hydraulic Regulation Part Disassembling
1.4.4.4.1 Demount hydraulic regulation device from hydraulic pipeline.
1.4.4.4.2 Demount hydraulic regulation device, air fan shell and twisting device.
1.4.4.4.3 Loosen hydraulic device bolts and take off impeller cover.
1.4.4.4.4 Demount hydraulic supporting seat, suspend impeller hydraulic regulation device on
overhead crane, loosen connection bolts and draw out hydraulic cylinder from bearing bushing of
main bearing.
1.4.4.4.5 Dismantle hydraulic cylinder and regulation device.
1.4.4.4.6 Check whether servo valve is blocked or not and clearance complies with standard or
not.
1.4.4.4.7 Replace all sealing fittings.
1.4.4.5 Blade Disassembling
1.4.4.5.1 Mark corresponding positions on impeller, hub and blade mandrill for the convenience of
reinstalling.
1.4.4.5.2 Dismantle tightening bolts of impeller and blades, lift blades out one by one with special
tool. Check blades that should be free from crackle, serious abrasion or dilapidation.
1.4.4.5.3 Blade should be cleaned with high pressure cleaner and then with brush; steel brush
should applied if there is static accumulated ash, no hammer is allowed to hit blade. No detergent
is allowed for cleaning to avoid resulting in corrosion of blades.
1.4.4.6 Hub Disassembling
1.4.4.6.1 Install flying rings on top of hub and lift hub in level with overhead crane, and then
dismantle hub and bearing cap.
1.4.4.6.2 Clean cooperation area of bearing and hub.
1.4.4.6.3 Install oil filler, oil pump, connection tube, screw thread bar and hydraulic tool for
dismantling hub.
1.4.4.6.4 Fill oil into two oil holes of hub with manual pump, when pressure reaches to 40Mpa,
start oil station of jack and keep pressure of manual pump. When hub moves slowly outwards,
overhead crane is always in a vertical line with hub; hub is slowly and evenly dismantled.
1.4.4.6.5 During drawing out hub, pull should not stop and keep constant until hub is taken off.
1.4.4.6.6 Dismantle special tool, clean bearing and hub, check whether aperture in hub and
bearing extension has corrosion, crack and scar or not.
1.4.4.7 Main Bearing Check
1.4.4.7.1 Heat up wheel-set at end of air fan and then dismantle it.
1.4.4.7.2 Dismantle end cover, lining, gland sealing, oil-splash and oil closing ring at two sides of
bearing tank shell.
1.4.4.7.3 Turn bearing box and make hub face down and then lift rotor out from bearing box slowly.
1.4.4.7.4 Clean and check bearing, main bearing and all parts; replace parts if it is seriously
abraded.
1.4.4.8 Bearing Box Inner Part Check
1.4.4.8.1 Clean and check oil-splash ring and oil closing ring.
1.4.4.8.2 Check and clean bearing.
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1.4.4.8.3 Clean and check end cover at two sides of bearing box.
1.4.4.8.4 Purge and clean bearing box inside and oil aperture.
1.4.4.9 Leafstalk Bearing Disassembling
1.4.4.9.1 Dismantle thrust plate and loosen leafstalk positioning block.
1.4.4.9.2 Dismantle precompression bring, bearing stock and sealing device, draw out guide
bearing subassemblies.
1.4.4.9.3 Take off safety ring, supporting ring, clip ring, balancing block and leafstalk.
1.4.4.9.4 Take out leafstalk sleeve carefully and then dismantle supporting bearing cover and
supporting bearing.
1.4.4.9.5 Dismantle guide bearing seat and drive sealing fitting, sealing ring and bearing stray.
1.4.4.9.6 Take off guide bearing.
1.4.4.9.7 Dismantle all parts for cleaning and checking, replace the parts with abrasion exceeding
regulated value or other defects.
1.4.4.9.8 Replace all sealing fittings of O type ring and tetrafluoroethylene gasket.
1.4.4.10.1 When installing new radial bearing, in order to confirm radial clearance of bearing group,
measure residual clearance before and after installing bearing to main shaft. It is not necessary to
measure after installing bearing into bearing box, because installing bearing in bearing box will not
or seldom result in decreasing of clearance.
1.4.4.10.2 Before installation of bearing, measure dimension of bearing inner sleeve and outer ring,
measure clearance between round and roller bearing with feeler gauge; move outer ring from
inner ring for the convenience of installing scale plate to measure bearing clearance.
1.4.4.10.3 Oil bath or induction heating is adopted for heating up supporting, thrust bearing and
closing ring in sequence.
1.4.4.10.4 Heat up bearing to 800C and 1000C in maximum. Oil bath or induction heating is
adopted for heating and sufficient oil with flashpoint above 2500C is used for heating.
1.4.4.10.5 Install supporting, thrust, bearing sleeve spacer ring, oil-splash ring and parts in bearing
box; during installation, rigid thing contacting with bearing inner & outer sleeves are prohibited.
1.4.4.10.6 After installing bearing onto main shaft, measure bearing clearance with feeler gauge; it
should be ensured that bearing, bearing sleeve and main shaft contact strictly.
1.4.4.10.7 Insert preassembled bearing subassemblies into bearing box from wheel-set side of
bearing box.
1.4.4.10.8 Measure and regulate clearances at all parts of bearing and tighten end cover of
bearing box.
1.4.4.10.9 Install all accessories and nuts at bearing end of bearing box.
1.4.4.11 Hub Installation
1.4.4.11.1 Check hub aperture and shaft end diameter with feeler gauge and micrometer, records
should be taken.
1.4.4.11.2 Clean antirust protection oil and other impurities on shaft end surface and hub.
1.4.4.11.3 Check keyways cooperation of hub and bearing and spread grease on cooperation
surface.
1.4.4.11.4 Install key on keyway at shaft end, lift hub to level of shaft end, align hub and make its
centerline be consistent with centerline of main bearing, turn main bearing until key and keyway of
hub are just face to face.
1.4.4.11.5 When installing hub with special jack, make sure that overhead and hub move
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synchronously.
1.4.4.12 Leafstalk Bearing Assembling
1.4.4.12.1 Blade guide bearing assemblies preassembling: put bolts at guide bearing of impeller
into bearing tray and put grease in guide bearing.
1.4.4.12.2 Press guide bearing of impeller into bearing tray, pay attention to centripetal thrust ball
bearing direction.
1.4.4.12.3 Put moving and stationary sealing device, install bearing seat on guide bearing and
moving sealing fittings.
1.4.4.12.4 Supporting bearing preassembling: screw bolts of supporting bearing into leafstalk nuts.
1.4.4.12.5 Put in supporting bearing and fill in proper 7014 high temperature grease.
1.4.4.12.6 Install leafstalk nuts on supporting bearing; install moving and stationary sealing device
and bearing end cover.
1.4.4.12.7 Put supporting bearing between supporting ring and guide ring and out it on installation
hole of guide bearing assembly.
1.4.4.12.8 Lie balancing weight on holes of supporting ring.
1.4.4.12.9 Preparation of assembling leafstalk: install leafstalk bearing sleeve into hole of impeller
shell and press it in with special tool, plastic must be used for lining during knock.
1.4.4.12.10 Check inner diameter of pressed leafstalk bearing sleeve.
1.4.4.12.11 Leafstalk and supporting bearing subassemblies assembling: put leafstalk key into
leafstalk, drill leafstalk through leafstalk bearing sleeve, balance weight, supporting bearing
assemblies until leafstalk screw threads touches screw threads of leafstalk nuts, and then screw it
for 2-3 rings.
1.4.4.12.12 Lift balance weight and support it with two same filler, insure balance weight with clip
ring.
1.4.4.12.13 Screw down leafstalk nuts until thrust bearing subassembly touches supporting ring
1.4.4.12.14 Put security ring on leafstalk nut
1.4.4.12.15 Guide bearing subassembly assembling: after hanging leafstalk on supporting bearing
subassembly, turn leafstalk for 180.
1.4.4.12.16 Press preassembled guide bearing assemblies into guide ring hole of impeller through
guide bearing subassemblies until end surface contacts with leafstalk nuts.
1.4.4.12.17 Push sealing fittings O type ring and tie bar between leafstalk and bearing tray, grease
should be plastered at groove of sealing fittings and cooperation surface.
1.4.4.12.18 Put pretensioning spring into between bearing tray of guide ring holes, grease should
be plastered groove of sealing fittings and cooperation surface.
1.4.4.12.19 Insure pretensioning spring with closing ring; loosen leafstalk nuts slightly and take
away filler under balance weight.
1.4.4.12.20 Screw down leafstalk nuts until pretensioning spring on bearing tray touches cone
annulus surface (torque is increased suddenly). It may be necessary to tighten leafstalk nuts a bit
to make groove aim at leafstalk nut, do not screw it in reversal.
1.4.4.12.21 Impeller and regulation bar assembling: insure leafstalk nut with security ring and
security piece, turn security ring until one end of hook get close to security piece.
1.4.4.12.22 Install regulation bar sliding pad at bearing end of regulation bar and fix it with closing
ring.
1.4.4.12.23 Preassemble pretensioning bolts and self-lock nuts at regulation bar.
1.4.4.12.24 Install regulation bar on bearing end leafstalk. Clean grease at bearing end of leafstalk
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cooperated with regulation bar before assembling; grease at surface of regulation bar should also
be cleaned.
1.4.4.12.25 Install sealing piece in impeller plate groove, spread grease in sealing grove on end
surface under impeller plate.
1.4.4.12.26 Fix leafstalk plate on leafstalk with bolts and lining sleeve
1.4.4.12.27 Regulate regulation bar and impeller to middle position, screw down the self-lock nuts.
1.4.4.12.28 Add pressure and inspect sealing of supporting bearing subassemblies.
1.4.4.12.29 Put hub, main bearing and assembled bearing box into air fan shell and fix it tightly.
1.4.4.13 Blade Installation
1.4.4.13.1 Check dismantled blades completely, they should be free from crack, double skin, sand
hole or aperture; inside destructive inspection should be done.
1.4.4.13.2 All blades are marked with serial number on hub; positions during installation should
comply with the ones during dismantling. During replacing new blades, alignment should be done
for blades.
1.4.4.13.3 Sealing pieces openings should stagger 180 to each other.
1.4.4.13.4 Keep blade and blade element eccentric. Tighten blades with tightening bolts.
1.4.4.13.5 Blades tightening bolts should be with middle position symmetric tightening. After
installation of all blades, check whether installation angles of blades are in consistent or not.
1.4.4.13.6 Measure and regulate clearance between blade top and wheel shell.
1.4.4.14 Hydraulic Regulation Device Installation
1.4.4.14.1 Before parts assembling, all contacting surfaces should be clean.
1.4.4.14.2 Install control hydraulic oil cylinder on supporting bearing, tighten bolts, and install hub
cover and supporting cover.
1.4.4.14.3 Tighten supporting cover on hub cover with three or four bolts.
1.4.4.14.4 Check alignment of valve piston. Fix micrometer on diffuser and put feeler gauge on
control hydraulic cylinder valve housing extended from control cover to align control hydraulic oil
cylinder and supporting cover.
1.4.4.14.5 Keep rotating bearing static during turning hub, which makes any error between rotating
gland sealing surface and bearing not influence right alignment.
1.4.4.14.6 Install other bolts on flange of supporting cover and tighten it, regulate eccentricity of
regulation control hydraulic oil cylinder and supporting cover continuously.
1.4.4.14.7 Install rotating gland sealing between rotating gland sealing and regulation flange,
tighten it with bolts.
1.4.4.14.8 Install rotating gland sealing for universal joint, oil inlet pipe, oil returning pipe and oil
leakage pipe.
1.4.4.14.9 Take off oil block of hub, install oil filling pipe and fill in lubricating oil.
1.4.4.14.10 Dismantle oil filling pipe and turn hub slowly until oil flows out from oil orifice, then
install oil block.
1.4.4.15.2 Install new sealing rope in bolts hole of inlet cone shell, push shell in and then tighten it.
1.4.4.15.3 Connect hydraulic tube of rotating gland sealing and check whether it has leakage or
not.
1.4.4.15.4 Check the clearance between impeller top and wheel shell and whether the clearance is
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within standard or not.
1.4.4.16 Clean Silencer
1.4.4.16.1 Demount silencer, clean polluted silencer with compressed air or industrial dust
collector.
1.4.4.16.2 When cleaning silencer, knock the silencer with a flat plate to make accumulated dust
break off. Pay attention to compressed air direction when cleaning with compressed air, its
direction should not be vertical to plate, make air nozzle parallel to plate as much as possible.
1.4.4.16.3 Holes in covering plates should be smooth for obtaining silencing effect.
1.4.4.17 Coupling Installation and Alignment
1.4.4.17.1 Heat up coupling evenly and install it on main shaft.
1.4.4.17.2 Put middle bearing of coupling on alignment tool of in inlet box inner shell.
1.4.4.17.3 Align it by regulating bolts at first and align it finally with micrometer and feeler gauge.
1.4.4.17.4 Check axial clearance between two half couplings.
1.4.4.17.5 Check angle error of coupling.
1.4.4.17.6 Tighten coupling, install coupling and middle shaft protection cover.
1.4.4.18 Hydraulic Pressure Oil Overhaul
1.4.4.18.1 Dismantle and check elements of oil pump and filter whether they have abrasion or oil
leakage or not; replace them according to actual condition.
1.4.4.18.2 Check and clean oil cooler, do the hydraulic test.
1.4.4.18.3 Clean oil tank, clean leakage points of tie-in and valves of all pipes.
1.4.4.18.4 Analyze lubricating oil; fill the oil tank to normal level with qualified lubricating oil.
1.4.5 FDF Overhaul Quality Standard
1.4.5.1 Preparation
1.4.5.2 Blade Overhaul Quality Standard
1.4.5.2.1 Blades should be fine and free from crack, double skin, sand hole and air hole, inner
destructive inspection should be done, leafstalk is tightened and bolts are free from looseness.
1.4.5.2.2 Moving blade regulation actuators work normally, blade regulation range is -30 +20,
its indication is right and consistent with actual openness.
1.4.5.2.3 Clearance between blade top and air fan shell is 2.7+0.5mm.
1.4.5.2.4 Blade bolts screwing torque is 294Nm.
1.4.5.3.1 Connection bolts should be free from abrasion or bending, screw threads should be
complete.
1.4.5.3.3 Heating up temperature for installing coupling in hot state should be no higher than
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150, flame is not allowed to heat up spring leaf directly.
1.4.5.3.4 Coupling concentricity permit error should be lower than 0.10mm and coupling end
deflection permit erroe should be lower than 0.06mm.
1.4.5.3.5 Maximum permit displacement at each end of coupling is: radial: 8.2mm axial:
4.0mm
1.4.5.3.6 Openness value of bearing end at two side of coupling should be no bigger than
31.5mm.
1.4.5.3.7 Coupling bolts tightening torque is 1370Nm.
1.4.5.3.8 Coupling security cover is fixed firmly and free from friction.
1.4.5.4 Hydraulic Regulation Device Overhaul Quality Standard
1.4.5.4.1 Concentricity of control hydraulic oil cylinder and supporting cover center should not
exceed 0.025mm.
1.4.5.4.2 Connection bolts tightening torque of hydraulic cylinder supporting body, supporting ring
and guide ring is 196Nm.
1.4.5.4.3 Hydraulic cylinder is free from oil leakage.
1.4.5.5 Outlet Damper Overhaul Quality Standard
1.4.5.5.1 Outlet damper should not exceed 1/5 and turn freely.
1.4.5.5.2 Cooperation clearance of outlet damper bearing and bearing sleeve should not exceed
0.30mm.
1.4.5.5.5 Outlet damper can open or close fully within 0 90 and operation is agile.
than 0.35mm.
than 0.35mm.
1.4.5.6.4 Main shaft bending degree is no higher than 0.05mm/m and plane windage is no bigger
than 0.02mm.
contacting angle is 120, contacting points at two sides should form a gradually transitional trace,
and sizes of contacting points should be the same of 1-2 points per square meter. The points are
evenly distributed.
1.4.5.6.7 Bearing heating temperature is within 800C1000C; oil flash point should be above
2500C when heating with oil bath method and bearing should not contact with bottom of heating
vessel.
1.4.5.6.8 Screwing torque of nuts at two ends of main shaft is 1100Nm, screwing torque of
connection bolts of bearing box and shell supporting ring is 441Nm.
1.4.5.7 Shell Air Box Overhaul Quality Standard
1.4.5.7.1 Air inlet room, shell, pressure expansion section, guide blade, supporters and expansion
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joints should be complete and fine and free from welding crack or fatigue crackle; bolts are free
from looseness.
1.4.5.7.2 Foundation of middle bearing, coupling and bearing box are complete; bolts should be
free from looseness, distortion or crack.
1.4.5.8 Air Fan Oil Station Overhaul Quality Standard
1.4.5.8.1 Oil tank is clean and free from impurities.
1.4.5.8.2 Clean oil filter element, clean residual oil in filter.
1.4.5.8.3 Clean shell and inner pipe wall of oil cooler, do the hydraulic test.
1.4.5.8.5 Hydraulic oil pressure should be within 24.5-29.4bar, lubricating oil pressure should be
no lower than 8bar and filter differential pressure should be lower than 1bar.
1.4.5.8.6 All tie-in, joint faces and valves of oil system should be free from oil leakage. Fire
wielding or argon arc welding should be done for rendering before welding pipelines.
should be normal.
1.4.5.9.3 All flanges, manholes and oil sealings should be strict and free from leakage;
through-flow part and blade have no impact and noise; there is no leakage of smoke, ash, oil and
water; damper switch should be agile and indication should be right.
1.4.5.10 Air Fan Oil Station Trial Run
1.4.3.10 Motor Lubricating Oil Trial Run
1.4.5.10.1 Oil system and cooling water pipe should be smooth andoil level is normal.
1.4.6 PAF Overhaul Process and Technics Method
1.4.6.1.1 Dsiamntle all pipelines and detection points connecting to air fan, corresponding position
1.4.6.1.2 Positons of all pipelines should be marked for the convenience of arranging temporary
warning signs.
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1.4.6.3 Rotor Assembly Dismantling
1.4.6.3.1 Disassemble blade regulation device, dismantle and separate regulation bearing from
indication bearing.
1.4.6.3.2 Separate security flat steel of main bearing box oil pipeline and main bearing box,
hydraulic pressure device oil pipeline and impeller regulation device and preventing hydraulic
pressure control head retortion from hydraulic control head of hydraulic regulation device.
1.4.6.3.3 Loosen connection bolts of half coupling of middle bearing and at air fan side.
1.4.6.3.4 Support middle bearing in air inlet box, and spring leaf coupling at compression motor
side.
1.4.6.3.5 Loosen connection bolts between main bearing box flange and supporting ring of lower
section of air fan shell.
1.4.6.3.6 Lift rotor assembly and put it into special bracket.
1.4.6.3.7 Keep it stable in level when lifting the rotor, and lift it upwards vertically from shell lower
section.
1.4.6.3.8 When rotor is laid on special bracket, its blade should not contact with ground or bracket.
1.4.6.4 Hydraulic Regulation Part Disassembling
1.4.6.4.1 Demount hydraulic regulation device from hydraulic pipeline.
1.4.6.4.2 Demount hydraulic regulation device, air fan shell and twisting device.
1.4.6.4.3 Loosen hydraulic device bolts and take off impeller cover.
1.4.6.4.4 Demount hydraulic supporting seat, suspend impeller hydraulic regulation device on
overhead crane, loosen connection bolts and draw out hydraulic cylinder from bearing bushing of
main bearing.
1.4.6.4.5 Dismantle hhydraulic cylinder and regulation device.
1.4.6.4.6 Check whether servo valve is blocked or not and clearance complies with standard or
not.
1.4.6.4.7 Replace all sealing fittings.
1.4.6.5 Blade Disassembling
1.4.6.5.1 Mark corresponding positions on impeller, hub and blade mandril for the convenience of
reinstalling.
1.4.6.5.2 Dismantle tightening bolts of impeller and blades, lift blades out one by one with special
tool. Check blades that should be free from crackle, serious abrasion or dilapidation.
1.4.6.5.3 Blade should be cleaned with high pressure cleaner and then with brush; steel brush
should should applied if there is static accumulated ash, no hammer is allowed to hit blade. No
detergent is allowed for cleaning to avoid resulting in corrosion of blades.
1.4.6.6 Hub Disassembling
1.4.6.6.1 Install flying rings on top of hub and lift hub in level with overhead crane, and then
dismantle hub and bearing cap.
1.4.6.6.2 Clean cooperation area of bearing and hub.
1.4.6.6.3 Install oil filler, oil pump, connection tube, screw thread bar and hydraulic tool for
dismantling hub.
1.4.6.6.4 Fill oil into two oil holes of hub with manual pump, when pressure reaches to 40Mpa,
start oil station of jack and keep pressure of manual pump. When hub moves slowly outwards,
overhead crane is always in a vertical line with hub; hub is slowly and evenly dismantled.
1.4.6.6.5 During drawing out hub, pull should not stop and keep constant until hub is taken off.
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1.4.6.6.6 Dismantle special tool, clean bearing and hub, check whether aperture in hub and
bearing extension has corrosion, crack and scar or not.
1.4.6.7 Main Bearing Check
1.4.6.7.1 Heat up wheel-set at end of air fan and then dismantle it.
1.4.6.7.2 Dismantle end cover, lining, gland sealing, oil-splash and oil closing ring at two sides of
bearing tank shell.
1.4.6.7.3 Turn bearing box and make hub face down and then lift rotor out from bearing box slowly.
1.4.6.7.4 Clean and check bearing, main bearing and all parts; replace parts if it is seriously
abraded.
1.4.6.8 Bearing Box Inner Part Check
1.4.6.8.1 Clean and check oil-splash ring and oil closing ring.
1.4.6.8.2 Check and clean bearing.
1.4.6.8.3 Clean and check end cover at two sides of bearing box.
1.4.6.8.4 Purge and clean bearing box inside and oil aperture.
1.4.6.9 Leafstalk Bearing Disassembling
1.4.6.9.1 Dismantle thrust plate and loosen leafstalk positioning block.
1.4.6.9.2 Dismantle precompression spring, bearing stock and sealing device, draw out guide
bearing subassemblies.
1.4.6.9.3 Take off safety ring, supporting ring, clip ring, balancing block and leafstalk.
1.4.6.9.4 Take out leafstalk sleeve carefully and then dismantle supporting bearing cover and
supporting bearing.
1.4.6.9.5 Dismantle guide bearing seat and drive sealing fitting, sealing ring and bearing stray.
1.4.6.9.6 Take off guide bearing.
1.4.6.9.7 Dismantle all parts for cleaning and checking, replace the parts with abrasion exceeding
regulated value or other defects.
1.4.6.9.8 Replace all sealing fittings of O type ring and tetrafluoroethylene gasket.
1.4.6.10.1 When installing new radial bearing, in order to confirm radial clearance of bearing group,
measure residual clearance before and after installing bearing to main shaft. It is not necessary to
measure after installing bearing into bearing box, because installing bearing in bearing box will not
or seldom result in decreasing of clearance.
1.4.6.10.2 Before installation of bearing, measure dimension of bearing inner sleeve and outer ring,
measure clearance between round and roller bearing with feeler gauge; move outer ring from
inner ring for the convenience of installing scale plate to measure bearing clearance.
1.4.6.10.3 Oil bath or induction heating is adopted for heating up supporting, thrust bearing and
closing ring in sequence.
1.4.6.10.4 Heat up bearing to 800C and 1000C in maximum. Oil bath or induction heating is
adopted for heating and sufficient oil with flashpoint above 2500C is used for heating.
1.4.6.10.5 Install supporting, thrust, bearing sleeve spacer ring, oil-splash ring and parts in bearing
box; during installation, rigid thing contacting with bearing inner & outer sleeves are prohibited.
1.4.6.10.6 After installing bearing onto main shaft, measure bearing clearance with feeler gauge; it
should be ensured that bearing, bearing sleeve and main shaft contact strictly.
1.4.6.10.7 Insert preassembled bearing subassemblies into bearing box from wheel-set side of
bearing box.
152
1.4.6.10.8 Measure and regulate clearances at all parts of beaing and tighten end cover of bearing
box.
1.4.6.10.9 Install all accessories and nuts at bearing end of bearing box.
1.4.6.11 Hub Installation
1.4.6.11.1 Check hub aperture and shaft end diameter with feeler gauge and micrometer, records
should be taken.
1.4.6.11.2 Clean antirist protection oil and other impurities on shaft end surface and hub.
1.4.6.11.3 Check kayway cooperation of hub and bearing and spread grease on cooperation
surface.
1.4.6.11.4 Install key on keyway at shaft end, lift hub to level of shaft end, align hub and make its
centerline be consistent with centerline of main bearing, turn main bearing until key and keyway of
hub are just face to face.
1.4.6.11.5 When installing hub with special jack, make sure that overhead and hub move
synchronously.
1.4.6.12 Leafstalk Bearing Assembling
1.4.6.12.1 Blade guide bearing assemblies preassembling: put bolts at guide bearing of impeller
into bearing tray and put grease in guide bearing.
1.4.6.12.2 Press guide bearing of impeller into bearing tray, pay attention to centripetal thrust ball
bearing direction.
1.4.6.12.3 Put moving and stationary sealing device, install bearing seat on guide bearing and
moving sealing fittings.
1.4.6.12.4 Supporting bearing preassembling: screw bolts of supporting bearing into leafstalk nuts.
1.4.6.12.5 Put in supporting bearing and fill in proper 7014 high temperature grease.
1.4.6.12.6 Install leafstalk nuts on supporting bearing; install moving and stationary sealing device
and bearing end cover.
1.4.6.12.7 Put supporting bearing between supporting ring and guide ring and out it on installation
hole of guide bearing assembly.
1.4.6.12.8 Lie balance weight on hole of supporting ring.
1.4.6.12.9 Preparation of assembling leafstalk: install leafstalk bearing sleeve into hole of impeller
shell and press it in with special tool, plastic must be used for lining during knock.
1.4.6.12.10 Check inner diameter of pressed leafstalk bearing sleeve.
1.4.6.12.11 Leafstalk and supporting bearing subassemblies assembling: put leafstalk key into
leaftstalk, drill leafstalk through leafstalk bearing sleeve, balance weight, supporting bearing
assemblies until leafstalk screw threads touches screw threads of leafstalk nuts, and then screw it
for 2-3 rings.
1.4.6.12.12 Lift balance weight and support it with two same filler, insure balance weight with clip
ring.
1.4.6.12.13 Screw down leafstalk nuts until thrust bearing subassemblies touches supporting ring
1.4.6.12.14 Put security ring on leafstalk nut
1.4.6.12.15 Guide bearing subassembly assembling: after hanging leafstalk on supporting bearing
subassembly, turn leafstalk for 180.
1.4.6.12.16 Press preassembled guide bearing assemblies into guide ring hole of impeller through
guide bearing subassemblies until end surface contacts with leafstalk nuts.
1.4.6.12.17 Push sealing fittings O type ring and tie bar between leafstalk and bearing tray, grease
should be plastered at groove of sealing fittings and cooperation surface.
153
1.4.6.12.18 Put pretensioning spring into between bearing tray of guide ring holes, grease should
be plastered at groove of sealing fittings and cooperation surface.
1.4.6.12.19 Insure pretensioning spring with closing ring loosens leafstalk nuts slightly and takes
away filler under balance weight.
1.4.6.12.20 Screw down leafstalk nuts until pretensioning spring on bearing tray touches cone
annulus surface (torque is increased suddenly). It may be necessary to tighten leafstalk nuts a bit
to make groove aim at leafstalk nut, do not screw it in reversal.
1.4.6.12.21 Impeller and regulation bar assembling: insure leafstalk nut with security ring and
security piece, turn security ring until one end of hook get close to security piece.
1.4.6.12.22 Install regulation bar sliding pad at bearing end of regulation bar and fix it with closing
ring.
1.4.6.12.23 Preassemble pretensioning bolts and self-lock nuts at regulation bar.
1.4.6.12.24 Install regulation bar on bearing end leafstalk. Clean grease at bearing end of leafstalk
cooperated with regulation bar before assembling; grease at surface of regulation bar should also
be cleaned.
1.4.6.12.25 Install sealing piece in impeller plate groove, spread grease in sealing grove on end
surface under impeller plate.
1.4.6.12.26 Fix leafstalk plate on leafstalk with bolts and lining sleeve
1.4.6.12.27 Regulate regulation bar and impeller to middle position, screw down the self-lock nuts.
1.4.6.12.28 Add pressure and inspect sealing of supporting bearing subassemblies.
1.4.6.12.29 Put hub, main bearing and assembled bearing box into air fan shell and fix it tightly.
1.4.6.13 Blade Installation
1.4.6.13.1 Check dismantled blades completely, they should be free from crack, double skin, sand
hole or aperture; inside destructive inspection should be done.
1.4.6.13.2 All blades are marked with serial number on hub; positions during installation should
comply with the ones during dismantling. During replacing new blades, alignment should be done
for blades.
1.4.6.13.3 Sealing pieces openings should stagger 180 to each other.
1.4.6.13.4 Keep blade and blade element eccentric. Tighten blades with tightening bolts.
1.4.6.13.5 Blades tightening bolts should be with middle position symmetric tightening. After
installation of all blades, check whether installation angles of blades are in consistent or not.
1.4.6.13.6 Measure and regulate clearance between blade top and wheel shell.
1.4.6.14 Hydraulic Regulation Device Installation
1.4.6.14.1 Before parts assembling, all contacting surfaces should be clean.
1.4.6.14.2 Install control hydraulic oil cylinder on supporting bearing, tighten bolts, and install hub
cover and supporting cover.
1.4.6.14.3 Tighten supporting cover on hub cover with three or four bolts.
1.4.6.14.4 Check alignment of valve piston. Fix micrometer on diffuser and put feeler gauge on
control hydraulic cylinder valve housing extended from control cover to align control hydraulic oil
cylinder and supporting cover.
1.4.6.14.5 Keep rotating bearing static during turning hub, which makes any error between rotating
gland sealing surface and bearing not influence right alignment.
1.4.6.14.6 Install other bolts on flange of supporting cover and tighten it, regulate eccentricity of
regulation control hydraulic oil cylinder and supporting cover continuously.
1.4.6.14.7 Install rotating gland sealing between rotating gland sealing and regulation flange,
154
tighten it with bolts.
1.4.6.14.8 Install rotating gland sealing for universal joint, oil inlet pipe, oil returning pipe and oil
leakage pipe.
1.4.6.14.9 Take off oil block of hub, install oil filling pipe and fill in lubricating oil.
1.4.6.14.10 Dismantle oil filling pipe and turn hub slowly until oil flows out from oil orifice, then
install oil block.
1.4.6.15.2 Install new sealing rope in bolts hole of inlet cone shell, push shell in and then tighten it.
1.4.6.15.3 Connect hydraulic tube of rotating gland sealing and check whether it has leakage or
not.
1.4.6.15.4 Check the clearance between impeller top and wheel shell and whether the clearance is
within standard or not.
1.4.6.16 Clean Silencer
1.4.6.16.1 Demount silencer, clean polluted silencer with compressed air or industrial dust
collector.
1.4.6.16.2 When cleaning silencer, knock the silencer with a flat plate to make accumulated dust
break off. Pay attention to compressed air direction when cleaning with compressed air, its
direction should not be vertical to plate, make air nozzle parallel to plate as much as possible.
1.4.6.16.3 Holes in covering plates should be smooth for obtaining silencing effect.
1.4.2.17 Repair Motor Bearing Pad
1.4.2.17.1 Discharge lubricating oil completely from bearing pad seat.
1.4.2.17.3 Dismantle upper cover of bearing pad and measure clearance of upper cover and
bearing pad and record it.
1.4.2.17.4 Demount bearing pad and dismantle oil-splash ring, measure clearance between
bearing pad and top of bearing and clearance between two sides, record original values well.
1.4.2.17.5 Prop up main bearing and take off bearing pads.
1.4.2.17.6 Check whether shaft surface is smooth or not, polish it with natural whetstone if there is
burr or indention.
1.4.2.17.7 Spread red lead powder on bearing pad after grinding it as per requirements.
1.4.2.17.8 Put bearing pad into bearing seat, low down main bearing, turn main bearing in air fan
rotating direction to grind bearing pad.
1.4.2.17.9 Take off bearing pad according to process 5 to check contacting condition of pad
surface; if it does not comply with standard, process 5, 6 and 7 should be done until bearing pad
grinding is qualified.
1.4.2.17.10 Clean bearing seat, bearing pad and main shaft, file burr on edge of bearing pad.
1.4.2.17.12 Reinstall bearing pad.
1.4.6.18 Coupling Installation and Alignment
1.4.6.18.1 Heat up coupling evenly and install it on main shaft.
155
1.4.6.18.2 Put middle bearing of coupling on alignment tool of in inlet box inner shell.
1.4.6.18.3 Align it by regulating bolts at first and align it finally with micrometer and feeler gauge.
1.4.6.18.4 Check axial clearance between two half couplings.
1.4.6.18.5 Check angle error of coupling.
1.4.6.18.6 Tighten coupling, install coupling and middle shaft protection cover.
1.4.6.19 Motor Lubricating Oil Station and Oil Station Overhaul
1.4.6.19.1 Dismantle and check elements of oil pump and filter whether they have abrasion or oil
leakage or not; replace them according to actual condition.
1.4.6.19.2 Check and clean oil cooler, do the hydraulic test.
1.4.6.19.3 Clean oil tank, clean leakage points of tie-in and valves of all pipes.
1.4.6.19.4 Analyze lubricating oil, fill the oil tank to normal level with qualified lubricating oil.
1.4.7 PAF Maintenance Quality Standard
1.4.7.1 Preparation
1.4.7.2 Blade Overhaul Quality Standard
1.4.7.2.1 Blades should be fine and free from crack, double skin, sand hole and air hole, inner
destructive inspection should be done, leafstalk is tightened and bolts are free from looseness.
1.4.7.2.2 Moving blade regulation actuators work normally, blade regulation range is 50.
1.4.7.2.3 Clearance between blade top and air fan shell is 1.9+0.5mm.
1.4.7.2.4 Blade bolts screwing torque is 93Nm.
1.4.7.3.1 Connection bolts should be free from abrasion or bending, screw threads should be
complete.
1.4.7.3.3 Heating up temperature for installing coupling in hot state should be no higher than
150, flame is not allowed to heat up spring leaf directly.
1.4.7.3.4 Coupling concentricity permit error should be lower than 0.10mm and coupling end
deflection permit error should be lower than 0.06mm.
1.4.7.3.5 Maximum permit displacement at each end of coupling is: radial: 8.8mm axial:
4.0mm
1.4.7.3.6 Openness value of bearing end at two side of coupling should be no bigger than
35.5mm.
1.4.7.3.7 Coupling bolts tightening torque is 1300Nm.
1.4.7.3.8 Coupling security cover is fixed firmly and free from friction.
1.4.7.4 Hydraulic Regulation Device Overhaul Quality Standard
1.4.7.4.1 Concentricity of control hydraulic oil cylinder and supporting cover center should not
exceed 0.025mm.
1.4.7.4.2 Connection bolts tightening torque of hydraulic cylinder supporting body, supporting ring
and guide ring is 47Nm.
156
1.4.7.4.3 Hydraulic cylinder is free from oil leakage.
1.4.7.5 Outlet Damper Overhaul Quality Standard
1.4.7.5.1 Outlet damper should not exceed 1/5 and turn freely.
1.4.7.5.2 Cooperation clearance of outlet damper bearing and bearing sleeve should not exceed
0.30mm.
1.4.7.5.3 Outlet damper can open or close fully within 0 90 and operation is agile.
than 0.35mm.
than 0.35mm.
1.4.7.6.4 Main shaft bending degree is no higher than 0.05mm/m and plane error is no bigger than
0.02mm.
contacting angle is 120, contacting points at two side should form a gradually transitional trace,
sizes of contacting points should be the same of 1-2 points per square meter. The points are
evenly distributed.
1.4.7.6.7 Bearing heating temperature is within 800C1000C; oil flash point should be above
2500C when heating with oil bath method and bearing should not contact with bottom of heating
vessel.
1.4.7.6.8 Screwing torque of nuts at two ends of main shaft is 1100Nm, screwing torque of
connection bolts of bearing box and shell supporting ring is 441Nm.
1.4.7.7 Shell Air Box Overhaul Quality Standard
1.4.7.7.1 Air inlet room, shell, pressure expansion section, guide blade, supporters and expansion
joints should be complete and fine and free from welding crack or fatigue crackle; bolts are free
from looseness.
1.4.7.7.2 Foundation of middle bearing, coupling and bearing box are complete; bolts should be
free from looseness, distortion or crack.
1.4.7.8 Motor Bearing Pad Overhaul Quality Standard
1.4.7.8.1 Cooperation tightening stress of bearing upper cover and upper bearing pad should be
0.02 0.04mm.
1.4.7.8.2 Alloy tile surface should be glabrous and show silvery white and free from yellow blow
spot, impurity, air hole, flaking, crack and indention.
1.4.7.8.3 Contact angle of bearing and bearing bushing is 65 90 and contacting points on
contacting edge should be with transitional trace. In permit contacting range, its contacting points
should be the same in size and evenly distributed in axial direction, check with printing color that it
should be 23 points/m2.
1.4.7.8.4 Clearance at top of bearing bush should be 1/1000 2/1000 of bearing diameter
157
(bigger value is applicable for smaller value), that is 0.2mm 0.4mm, if bearing bush clearance
exceeds this range, milling and digging method should be adopted for processing joint face of
bearing bush.
1.4.7.8.5 For the clearances at two sides of new bearing bush, insert 15mm 20mm along
bearing with 0.15mm feeler gauge; and insert 15mm 20mm with 0.03mm feeler gauge for old
bearing bush.
1.4.7.8.6 Bearing bush should not turn on bearing seat and contacting points on joint face of
bearing bush should be evenly distributed and no less than 1 point/ m2; filling up is not allowed
generally.
1.4.7.8.7 Contacting points of bearing bush end surface and bearing shoulder should be evenly
distributed and no less than 2 points/ m2, its bearing bush round angle should not contact with
round angle of bearing shoulder.
1.4.7.8.8 Oil-splash ring should be round and its ring thickness should be even, its surface should
be smooth, its interface should be firm, oil ring in grove has no block and keep turning in even
speed with the bearing.
1.4.7.9 Air Fan Oil Station Overhaul Quality Standard
1.4.7.9.1 Oil tank is clean and free from impurities.
1.4.7.9.2 Clean oil filter element, clean residual oil in filter.
1.4.7.9.3 Clean shell and inner pipe wall of oil cooler, do the hydraulic test.
1.4.7.9.5 Hydraulic oil pressure should be within 24.5-29.4bar, lubricating oil pressure should be
no lower than 8bar and filter differential pressure should be lower than 1bar.
1.4.7.10 Motor Lubricating Oil Overhaul Quality Standard
1.4.7.10.1 Clean oil tank that should be free from impurities.
1.4.7.10.2 Clean oil filter element, discharge residual oil completely from filter.
1.4.7.10.3 Clean oil cooler shell and inner pipe walls, do the hydraulic test.
1.4.7.10.5 Oil pump outlet pressure should not be lower than 0.20Mpa, motor bearing pad
supplying oil pressure should be lower than 0.16Mpa.
should be normal.
1.4.7.11.3 All flanges, manholes and oil sealing should be strict and free from leakage;
through-flow part and blade have no impact and noise; there is no leakage of smoke, ash, oil and
water; damper switch should be agile and indication should be right.
1.4.3.12 Motor Lubricating Oil Station and Hydraulic Oil Station Trial Run
1.4.3.12.1 Oil system and cooling water pipe should be smooth and oil level is normal.
158
1.4.8 Gas & Air Duct and Damper Overhaul Maintenance and Process Method
1.4.8.1 Preparation
1.4.8.1.1 Prepare lighting, voltage of which should be 12-24V; insulation of electric-driven tools are
fine.
1.4.8.1.2 Build up scaffold well outside.
1.4.8.2 Cold & Hot Air Duct Overhaul
1.4.8.2.1 Open coal and hot air duct manhole for ventilation.
1.4.8.2.2 Check air leakage.
1.4.8.2.3 Tie wire should be complete and free from welding crack, crackle or damage.
1.4.8.2.4 Incabloc should be complete and free from damage.
1.4.8.2.5 Middle isolation plate should be free from crackle and welding crack.
1.4.8.2.6 When welding cold & hot air duct by replacing, damaged pipe should be cut off first and
new steel plate should be the same in size with the cut one. When welding incabloc, welding crack
part should be fixed and welded well.
1.4.8.2.7 After check, fill up joint face of manhole and close manhole well, it should be strict and
free from leakage after tightening nuts.
1.4.8.2.8 Regulate tie bars of cold and hot air duct.
1.4.8.3 Gas Duct Overhaul
1.4.8.3.1 Open coal and hot gas duct manhole for ventilation.
1.4.8.3.2 Check gas leakage.
1.4.8.3.3 Tie wire should be complete and free from welding crack, crackle or damage.
1.4.8.3.4 Incabloc should be complete and free from damage.
1.4.8.3.5 Middle isolation plate should be free from crackle and welding crack.
1.4.8.3.6 When welding gas duct by replacing, damaged pipe should be cut off first and new steel
plate should be the same in size with the cut one. When welding incabloc, welding crack part
should be fixed and welded well.
1.4.8.3.7. After check, fill up joint face of manhole and close manhole well, it should be strict and
free from leakage after tightening nuts.
1.4.8.3.8 Regulate tie bars of gas duct.
1.4.8.4 Damper in Gas & Air Duct Overhaul
1.4.8.4.1 Dismantle connection bolts of transmission lever.
1.4.8.4.2 Dismantle bearing sleeves at two sides of damper shaft.
1.4.8.4.3 Dismantle small shaft at two ends of damper and lift damper with chain block for
overhaul.
1.4.8.4.4 Reinstall in sequence after overhaul is completed.
1.4.9 Gas & Air Duct and Damper Overhaul Quality Standard
1.4.9.1 Cold & Hot Air Duct Quality Standard
159
1.4.9.1.1 It should be replaced if cold & hot air duct abrasion exceeds 1/2 of its designed
thickness.
1.4.9.1.2 Cold & hot air duct should be free from vibration and air leakage during operation.
1.4.9.1.3 Cold & hot air duct manhole should be free from air leakage.
1.4.9.1.4 Air duct lever tensioning stress is proper and insulation facilities are complete.
1.4.9.1.5 No foreign material is left after air duct overhaul, check and count working personnel and
tools before closing manhole valves.
1.4.9.2 Gas Duct Quality Standard
1.4.9.2.1 It should be replaced if gas duct abrasion exceeds 1/2 of its designed thickness.
1.4.9.2.2 Gas duct should be free from vibration and air leakage during operation.
1.4.9.2.3 Gas duct manhole should be free from air leakage.
1.4.9.2.4 Gas duct lever tensioning stress is proper and insulation facilities are complete.
1.4.9.2.5 No foreign material is left after gas duct overhaul, check and count working personnel
and tools before closing manhole valves.
1.4.9.3 Gas & Air Duct Damper Quality Standard
1.4.9.3.1 Abrasion of damper should not exceed 1/3 of its thickness and it is free from crack and
dilapidation.
1.4.9.3.2 Supporting bearing bush abrasion does not exceed 1/5 of aperture, sealing stuffing of
bearing sleeve is proper.
1.4.9.3.3 Damper can be opened or closed in agility and regulation position is right. For shatter
dampers, all dampers must be opened or closed synchronously.
1.4.9.3.4 Damper bearing and flange are free from air leakage.
1.5.1 Safety
1.5.1.6 Impeller must earth when welding to avoid burning bearing.
160
1.5.2 Health
1.5.2.1 Measures for preventing breathing dust should be taken when entering into gas duct and
IDF.
completed.
161
Chapter Air Preheater Maintenance Regulation

This chapter is applicable for 33.5-VI(T)-2333-QMR type air preheater (produced by Harbin
Boiler Factory Co., Ltd.) maintenance and overhaul and to offer references and guides for the
maintenace personnel.
Quoted material:
Amercia ABB (ALSTOM now) Air Preheater Engineering Co., Ltd.
Harbin No. 3 Power Plant Maintenance Regulation (Air Preheater Part)
1.1 Air Preheater Equipment Brief Introduction and Parameter
1.1.1 Air Preheater Equipment Brief Introduction
Ljungstorm Air Preheater Working Principle:
Ljungstorm Air Preheater absorbs heat from gas, the heat is then transferred to cold air
through continuously rotatating heat transferring elements consists of special type metal plates.
Thousands high efficiency heat transferring elements are close laid in sector storehouse, in
which column shell of rotors are radially comparted; rotor shell is installed outside rotor and two
ends of rotor shell connects with gas-air duct. Radial sealing and bypass sealing are installed in
preheater, which forms circulation of preheater, in half of which flows gas and in the other half of
which flows air. When rotor turns slowly, gas and air flows through heat transferring elements
alternatively, heat transferring element absorbs heat from hot gas, and then these heat
transferring elements are eroded by air flow and release stored heat. Thus, air temperature has
been increased a lot.
Rotary air preheater in this unit is type, thrisection storehouse mode and inner arranged
supporting bearing is adopted.
1.1.2 Air Preheater Main Performance Parameters:
Table 2-1
Name Unit Value
Type Three compartment rotary
Ljungstorm air preheater
33.5-VI(T)-2333-QMR
Quantity Set 4 sets/ 2boilers
High temperature section heat transferring Q235
element material
High temperature section heat transferring mm 0.5
element thickness
High temperature section heat transferring mm 1000
element height
High temperature section heat transferring m2 26808 (single side)
element area
High temperature section heat transferring t 133.94
element total weight
Middle temperature section heat transferring Q235
element material
Middle temperature section heat transferring mm 0.5
162
Name Unit Value
element thickness
Middle temperature section heat transferring mm 1000
element height
Middle temperature section heat transferring m2 26808 (single side)
element area
Middle temperature section heat transferring t 133.94
Low temperature section heat transferring Corten steel
element material
Low temperature section heat transferring mm 0.8
element thickness
Low temperature section heat transferring mm 300
element height
Low temperature section heat transferring m2 8042 (single side)
element area
Low temperature section heat transferring t 63.12
Heat transferring element total height mm 2333
Top, bottom section sector plate Fixed, can not be regulated
Axial arc plate Fixed, can not be regulated
Air preheater bearing lubrication and cooling Oil bath lubrication, bearing
type water cooling
Cooling water amount t/h 20
Air preheater cooling water parameter 0.49Mpa, <38
(pressure, temperature)
Air preheater rotor diameter mm 15710
Air preheater rotor height m 2.977
Shell height M 8.299
Air preheater rotor total weight t 11.936
Air preheater rotor rotating speed r/min Normal running 0.90;
Frequency conversion
rotating speed 0.25
Air preheater drive motor type Y200L1-6 B5 type 18.5KW,
380V,37.7A , 970 RPM
IP56, F grade insulation
Air preheater drive motor quantity Set 2
Air preheater drive motor quantity rotating r/min 970
speed
Air preheater drive nameplate power kW 18.5
Air preheater drive reducer type REDUCER ASS Y
163
Name Unit Value
MOTO bevel gear reduction box Speed reducing ratio 12.681
ZF108-K4-160
Lubricating oil litre 5.3 viscidity VG220
BWN142 flexible coupling 2 sets
Drive mechanism bearing sleeve lock plate SD280-91
Top guide roller bearing SKF23972 CAC/W33
Lubricating oil liter N680 1000# middle load or
heavy load extreme
industrial gear oil
consumption 43.5L
Bottom supporting bearing Thrust radial roller bearing
294/710E.MB
Lubricating oil liter N680 1000# middle load or
heavy load extreme
industrial gear oil
consumption 150L
Top bearing lock plate SD280-71
Soot blower manufacturer Diamond or Clyde
Soot blower type of air preheater Flex type
Soot blower length of air preheater m 6.708
Soot blower sets of air preheater Set 1
Air prehater soot blower quantity Set 1
Minimum fire fighting water flow t/h 300
Fire fighting water parameter 0.49Mpa-0.52Mpa
Cleaning water amount t/h 185/set soot blowerinterim
Cleaning water parameter 0.49Mpa

Air preheater rotor total weight (including T 443
element and sealing plate)
Supporting bearing device quality T 6.15
Guide bearing device quality T 2.912
Heaviest hot end heat transferring element kg 533
box quality
Heaviest cold end heat transferring box kg 240
quality
Air preheater total weight T 734
Air preheater top and button bearing T 14
maintenance overhaul and outer
protection plate
1.2 Air Preheater Overhaul Sort, Cycle and Period
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Sort Cycle Period
1.3 Air Preheater Overhaul Items
1.3.1 Check radial, axial, circumferential direction and center sealing system (A, B, C)
1.3.2 Check rotor drive mechanism lubrication (A, B, C)
1.3.3 Check rotor top and bottom bearing lubrication (A, B, C)
1.3.4 Check drive motor lubrication (A, B, C)
1.3.5 Soot blowers functional test (A, B, C)
1.3.6 Check fire fighting system (A, B, C)
1.3.7 Check fire local cabinet (A, B, C)
1.3.8 Check fire detector (A, B, C)
1.3.9 Check ahs block and abrasion of heat exchanging element surface (A, B, C)
1.3.10 Regulate and replace radial, axial and circumferential direction sealing (A)
1.3.11 Check air preheater drive mechanism (A)
1.3.12 Check air preheater top and bottom bearing (A)
1.3.13 Replace heat transferring element (T, A, B)
1.3.14 Replace sector plate (A, B)
1.3.15 Replace hot end heat exchanging element (A, B, C)
1.3.16 Clean middle temperature end (A, B)
1.3.17 Weld welding line of radial compartment plate (A, B, C)
1.3.18 Repair and replace serious abraded part of cold end support (A)
1.3.19 Replace gland packing of gland sealing of air preheater (A, B, C)
1.3.20 Fix air preheater cold end shield and replace seriously abraded shield (A, B, C)
1.3.21 Fix or replace flex joint shield at inlet of air preheater (A)
1.3.22 Block leakage of shell of air preheater (A, B)
1.3.23 Mend sector plate and arc plate of air preheater (A, B)
1.3.24 Fix air preheater support (A)
1.3.25 Repair and clean lubricating oil system (A, B, C)
1.3.26 Replace titanium disc of spraying water pipe of air preheater (A, B, C)
1.3.27 clean air preheater with water (A, B, C)
Notice: above overhaul working procedure is the one including all important and special items
of air preheater, execute the related items accordingly, among which:
T Important and special item;
A Common major overhaul item;
B Minor overhaul item
C Temporary overhaul item.
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1.4 Air Preheater Overhaul Process, Process Method and Quality Standard
1.4.1 Preparation
1.4.1.1 Preparation before Maintaining and Overhaul
1.4.1.1.1 Safety Description
1.4.1.1.1.1 Harmful gas
During normal operation of the power plant, a certain SO2 is contained in hot gas, its
concentration depends on sulphur content in combustion and burning condition. When it is
necessary to stop air preheater for examining inside or maintaining inside of gas & air duct, cooling
and ventilation should be done for it properly to eliminate harmful gas. Rotor should keep rotating
during cooling initial stage to avoid distortion of rotor and sealing strip, open vent hole to vent air
and avoid dewing. After air preheater is cooled down (temperature should be lower than 60 to
avoid scald accident), stop rotor and cut off power supply of the motor. Following data are harm to
personnel body of SO2 with different concentration:
5ppm permit limit value
3-5ppm influence olfaction
8-12ppm stimulate throat
20ppm cause cough
50-100ppm stay for one hour
200-500ppm stay for half an hour
1.4.1.1.1.2 Acidic substance
According to different factors of sulfur content and excessive air coefficient during
combustion, most sulfur during burning is changed to be SO2, but there are still 1-5% sulfur is
changed to be SO3. SO3 and vapor in gas forms vitriol, which erode metal and endanger personnel
safety seriously. Before entering into gas & air duct, working personnel should check whether
there is corrosion at supporting place of inner platform or not, whether platform structure is reliable
or not.
All the working personnel should realize above potential danger and wear proper safety belt,
protection clothes, protective respirator and protection glasses.
1.4.1.1.1.3 HP superheating steam
Before entering into gas & air duct or demounting manhole for repairing soot blowers, first
check whether steam isolation valve on soot blower is completely closed and locked or not. If there
is leakage at the isolation valve, upriver steam source should be cut off. Other hidden troubles
causing pipeline leakage and threatening personnel safety should be avoided.
1.4.1.1.1.4 Electric equipment
Power supply of drive motor must be cut off before doing work inside air preheater to avoid
mechanical wound caused by abnormal starting.
It must be ensured that power supply is cut off and locked before repairing electric
equipments in air preheater.
1.4.1.1.1.5 Notices before repairing air preheater body
obtain work permit ticket
related operators are familiar with safety operation regulation
make sure air preheater power supply is cut off
open gas & air duct manhole
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before entering into air preheater, check inside of air preheater, temperature of which
should be proper and it should be free from harmful gas; Make sure that inner ventilation
conditions are fine
Check whether steam and flushing water source of soot blowers are completely cut off or
not, check whether water supply of fire fighting device is completely cut off or not.
Prepare lighting equipments for work inside air preheater
Prepare scaffold and safety net in gas & air duct at bottom of air preheater, make sure that
supports are safe and reliable.
make sure that no one turns rotor of turning gear manually under condition of no any
precaution when there is no one working inside air preheater
Wear protection clothes and respirator

1.4.1.1.2 Equipment Running State before Overhaul
Before overhaul, working principal should check completely and record equipment running
state, date should be recorded for three (3) times with one (1) week space in-between.
Record table is as following:
Air preheater running state statistics
Item First data Second data Third data
Primary air inlet, outlet
temperature
Secondary air inlet, outlet

temperature
Flue gas inlet, outlet

temperature
Flue gas inlet, outlet

pressure MPa
Primary air inlet, outlet
pressure MPa
Secondary air inlet, outletp
pressure MPa
Primary air leakage
coefficient %
Total air leakage
coefficient %
Motor current A
Environment
temperature
Existent defect
Existent leakage points
1.4.1.1.3 Material preparation for maintenance
Commonly used materials are listed in following table, properly increase or decrease according
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to maintenance class and actual condition during execution.
Specificatio Quantity
NO. Name n and Unit
type T A B C
1 Bearing lubricating oil Mobil 639 Kg

2 Drive mechanism kg 170 170 170 170
lubricating oil
3 Drive mechanism Butter kg 10 10 10 10
grease
4 Jack oil Mobil 26 kg 40 40 40 40
5 Kerosene kg 10 10 5 5
6 Molybdenum kg 5 5 5 5
disulfide
7 Bolt loosening agent Barrel 4 4 2 1
8 High temperature Barrel 2 2 2 2
plugging agent
9 Plastic cloth M2 50 30 30 30
10 White cloth m 10 10 5
11 clout kg 10 10 10 5
12 #0 #1 #2 Piece 20 for 30 for 20 for 10 for
Emery cloth
each each each each
13 Cotton yarn cloth M 10 10 10 5
14 Insulation tape coil 2 3 2 2
15 Electric torch Piece 5 5 3 2
16 Battery Piece 40 30 20 20
17 Battery for electric 2.5V 3.8V Box 1 1 1 1
torch
18 Bulb for portable light 36V Piece 15 10 10 10
19 Connector of Piece 5 5 5 3
portable light
20 Magnetic connector 500W Piece 5 5 5 3
21 Bulb 500W 100W Piece 8 8 8 3
22 Sealing glue 703 Bag 5 5 3 2
23 Sealing glue 587 Bag 3 3 2
24 Teflon belt Box 5 5 5 5
25 Woven bag Piece 20 20 10 5
26 Waterline Two phases m 200 200 200 100
27 Oil resistant asbestos 2mm 5 3 2 1
gasket
28 Oil resistant asbestos 1mm 2 2 2 1
gasket
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Specificatio Quantity
NO. Name n and Unit
type T A B C
29 Fish paper gasket 0.5mm 1 1 1
32 Oil resistant rubber 2mm 0.2 0.2 0.2 0.2
33 Oil resistant rubber 3mm 10 10 10 5
34 High pressure 1616 20 20 20 15

oiliness gland
packing
35 Oiliness gland 88 10 10
packing
36 Asbestos belt 10 Circle 1 1
37 6mm Ton 0.5 1 0.5 0.5
Steel plate
38 8mm Ton 0.5 1 0.5 0.5
Steel plate
39 10mm Ton 0.5 1 0.5 0.5
Steel plate
40 12mm Ton 0.5 1 0.5 0.5
Steel plate
41 16mm Ton 0.5 1 0.5 0.5
Steel plate
42 Corrugated steel 2 0.5 0.5 0.5 0.5
plate
43 Whetstone Block 2 2 2
44 Red lead powder 0.1 0.1 0.1
45 Angle iron 50 30 50 30 10
46 Angle iron 40 30 50 30 10
47 Angle iron 30 20 20 10 10
48 Flat iron 50 40 30 30 10
49 Flat iron 40 40 30 30 10
50 Reinforcing steel bar =6 20 20 10 10
51 Reinforcing steel bar =8 20 20 10 10
52 Reinforcing steel bar 10 20 20 10 10
53 Reinforcing steel bar 12 20 20 10 10
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1.4.1.1.4 Preparation for Overhaul Spare Parts
All the following quantities are for single unit:
No. Name Specification Unit Quantity
1 Drive mechanism CDA500/CDA250/ZF108-K4-160 Set 1

2 Top guide bearing double-row radial spherical roller
bearing : 23192
Disc
3 Bottom supporting Thrust radial roller bearing:
Disc
bearing 294/710E.MB 1
4 Drive motor Y200L1-6 B5
type18.5KW,380V,37.7A , 970 Set
RPM double shaft extension
5 Transducer 690PC 15KW Set

6 Lubricating oil for bearing N680 1000# middle load or high
Liter
load extreme industrial gear oil 200
7 Lubricating oil for drive N320 middle load or high load
Liter
device extreme industrial gear oil 43.5
8 Hot end radial sealing
piece, pressing plate Set
and tightening fittings
9 Cold end radial sealing
piece, pressing plate Set
and tightening fittings
10 Axial sealing piece,
pressing plate and Set
tightening fittings
11 Bottom outer edge
circumferential Set
sealing ring
12 Top outer edge
circumferential Set
sealing ring
13 Bottom inner edge
circumferential Set
sealing ring
14 Top inner edge
circumferential Set
sealing ring
15 Bottom center sleeve
Set
sealing piece
16 Top center sleeve sealing
Set
piece
17 Center sleeve sealing
15*15 Set 2
gland packing
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18 Drive device first stage

Set
speed reducing gear
Set
speed worm
20 Drive device second
Set
stage speed worm
21 Bearing of drive device
first stage speed Set
reducing box
first stage worm Set
speed reducing box
second stage worm Set
speed reducing box
24 Gland sealing of drive
device second stage
Set
worm speed
reducing box
25 Top bearing oil level
Set
indicator
26 Bottom bearing oil level
Set
indicator
27 Fire detector
Set 2
(thermocouple)
28 Rotor speed lose alarm
Set 4
detector
29 Top bearing oil
Set 2
temperature detector
30 Bottom bearing oil
Set 2
temperature detector
worm speed
Set
reducing box torque
arm
32 Drive device second
stage worm speed
Set
reducing box torque
arm
33 Sealing gasket of soot
Set
blower
34 Drive motor of soot
Set 1
blower
35 Soot blower nozzle Piece 2
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36 Fire fighting nozzle Piece 2

37 Hot end heat exchanging
2.78DU, 1000*0.5 Set
element
38 Middle temperature end
heat exchanging 2.78DU, 1000*0.5 Set
element
39 Cold end heat
2.78DU, 300*0.8 Set
exchanging element
1.4.1.1.5 Preparation for Maintenance Tools and Apparatus
1.4.1.1.5.1 General tools
No. Name Specification Unit Quantity Overhaul grade
1 Steel punch Digital Set 1 TA
2 Mark pen middle, coarse Piece 1 TABC
and thin
3 Adjustable spanner 6 inch Piece 1 TABC
6 Open end spanner 13 Piece 1 TABC
9 Double offset ring 2427 Piece 5 TABC

spanner
spanner
spanner
12 Double offset ring 27-30 Piece 2 TABC
spanner
13 Moment spanner 24,36 set 1 TAB
14 Open-end wrench S36 Piece 1 TAB
17 Inner hexagon S6 Piece 1 TAB
spanner
spanner
spanner
20 Tap M8,10,12,16 Set 1 for each TABC
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21 Brush 2 4 Piece 3 for each TABC
22 Cased ruler 3 Piece 1 TAB
23 Cloth scissor Piece 1 TAB

24 Hammer 1.5B Piece 1 TABC
25 Hammer 2.5B Piece 1 TABC
26 Sledge 12B Piece 1 TABC
27 Sledge 18B Piece 1 TAB
28 Flat screwdriver 755 Piece 1 TABC
29 Flat screwdriver 2007.5 Piece 1 TAB
30 Cross screwdriver 1505 Piece 1 TABC
31 Crowbar 5001000 Piece 2 for each TAB
32 Saw bow Piece 1 TAB

33 Pipe wrench 450 Piece 1 TABC
34 Half round file 12" Piece 1 TABC
35 Round file 10 Piece 1 TABC
36 Triangle file 12" Piece 1 TABC
37 Scraper 200 Piece 2 TABC
38 Flat scraper 200 Piece 1 TABC
39 Cross chisel Piece 1 TABC
40 Jack 5T Set 2 TAB
41 Jack 50T Set 1 TA
42 Pliers Piece 1 TABC
1.4.1.1.5.2 Electric tools
1 Electric driller 13 Set 1 TA
2 Angle grinder 100 Set 1 TA
3 Portable cutting 150 Set 1 TABC
machine
4 Filtering machine Set 1 TABC
5 Electric grinder Set 1 TABC
6 Bobbin winder 100m Set 1 TABC
wheel
7 Transformer of 36V Set 1 TAB
traveling
crane
8 Light 500W Piece 4 TAB
9 Light 100W Piece 4 TABC
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1.4.1.1.5.3 Lifting tools
No. Name Specification Unit Quantity Overhaul
grade
1 Electric hoist 5T Set 2 TAB
2 Chain sling 5T Set 2 TA
3 Chain sling 3T Set 1 TAB
4 Chain sling 2T Set 2 TAB
1.4.1.1.5.4 Special tools
No. Name Specification Unit Quantity Overhaul
grade
1 Jack oil pump set 1 TA
2 Lead screw M40 Piece 2 TA
3 Lead screw frame Set 1 TA
4 Lead screw welding 23035040 Piece 1 TABC
screw
5 Flying rings M24 Piece 2 TA
6 Dismantle tripod of Piece 1 TAB
bearing
1.4.1.1.5.5 Measuring tools
1 Outside micrometer 025 Piece 1 TAB
2 Outside micrometer 175180 Piece 1 TAB
3 Inside micrometer 50600 Piece 1 TAB
4 Feeler gauge 150 Piece 3 TABC

5 Percentage meter 010 Piece 2 TAB
6 Magnetic force Piece 2 TAB

percentage
meter support
7 Frame gradiometer 250 Piece 1 TAB
8 Water level Piece 1 T
9 Steel ruler 150 Piece 1 TABC
10 Steel ruler 300 Piece 1 TABC
11 Steel ruler 500 Piece 1 TAB
12 Vernier caliper 150 Piece 1 TABC
1.4.1.2 Preparation for Overhaul
1.4.1.2.1 Decide construction principal
1.4.1.2.1.1 Organize properly, divide work clearly and be responsible for safety, quality and
civilized construction.
1.4.1.2.1.2 Disclosure technical measures and safety measures (including measures controlling
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danger factors) before starting work.
1.4.1.2.1.3 Check whether safety measures are perfect or not, check safety status at site and of
safety tools and instruments, supervise application condition of lifting tools, safety appliance and
motor- driven tools and instruments.
1.4.1.2.1.4 Execute overhaul process quality standard strictly, quality records should be right.
1.4.1.2.1.5 Overhaul site and parts should comply with safety & civilization production regulations.
1.4.1.2.1.6 Designate special person to make records and make sure records should be true and
right.
1.4.1.2.1.7 Supervise safety of maintenance personnel as per requirements of Code for Safety
Production of Power Industry.
1.4.1.2.2 Arrange work site and check lighting facilities.
1.4.1.2.3 Discuss and carry out overhaul items, control overhaul schedule.
1.4.1.2.4 Transact work permit ticket, work can only be started after all safety measures and
danger factor control measures are well executed.
1.4.1.2.5 Work can be executed in advance during operation:
1.4.1.2.5.1 Test bearing jack and special jack oil pump with special tools
1.4.1.2.5.2 Install special orbit of lower bearing
1.4.1.2.5.3 Check welding of gearing of air preheater
1.4.1.2.5.4 Check and confirm maintenance spare parts
1.4.2 Air Preheater Overhaul Process, Process Method and Quality Standard
Before entering into air preheater for repairing, firstly overhaul work permit ticket should be
issued, working with no ticket is not allowed. When inner temperature decreases to be lower than
40, use #10 channel steel to fix rotor and stator of air preheater in clockwise and anticlockwise
to avoid turning.
1.4.2.1 Stop Air Preheater for Check
Main content of check includes:
1.4.2.1.1 Check corrosion, ash blocking and abrasion conditions of heat accumulation
components:
1.4.2.1.2 Check positioning clearance and abrasion of upper and lower radial gaskets, axial
gaskets and circumferential direction sealing gaskets.
1.4.2.1.3 Check abrasion and sealing clearance of sealing fittings of center cylinder
1.4.2.1.4 Check abrasion of upper and lower sector plate and arc plate
1.4.2.1.5 Check abrasion and corrosion of air preheater shell
1.4.2.1.6 Check abrasion of transitional gas & air duct and supporting structure
1.4.2.1.7 Open cold end inspection door, check completeness and fastness of cold end guard
plate
1.4.2.1.8 Check level degree and round degree of rotor periodically
1.4.2.1.9 Check that air preheater ash hopper is smooth and free from ash accumulation
1.4.2.1.10 Check inlet & outlet transitional connection completeness of all gas & air ducts
1.4.2.1.11 Check that dampers of inlet gas duct or air duct outlet are free from abrasion and act
freely
1.4.2.1.12 Check abrasion and corrosion of inlet gas duct, outlet air duct supports and other parts
that may cause block of air preheater
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1.4.2.1.13 Check position and soot blowing effect of soot blowers
1.4.2.1.14 Check that functions of fire fighting system are normal and whether there is bursting
disc
1.4.2.1.15 Check that fire detectors function is normal
1.4.2.1.16 Check that top and bottom rotor shafts sealing is reliable and free from air leakage
1.4.2.1.17 Check lubricating oil quality and oil level of lower section bearing. Make sure that oil
level indication is reliable
1.4.2.1.18 Check upper section guide bearing lubricating oil quality and oil level, make sure that oil
level indication is reliable; check that cooling water system is smooth and free from leakage or
accumulated dirty.
1.4.2.1.19 Check that tightening stress of bearing lock plate and gearing lock plate comply with
standard
1.4.2.1.20 Check that lubrication of gearing is fine, check abrasion of speed reducing mechanism
periodically.
1.4.2.1.21 Check installation direction of resisting torque arm is right and its supporting seat is
reliable.
1.4.2.1.22 Check and lubricate motor bearing
1.4.2.1.23 Check lubricating oil vent hole of primary speed reducing box of gearing
1.4.2.1.24 Check oil level of primary speed reducing box of gearing
1.4.2.1.25 Check lubricating oil level of top and bottom bearing box
1.4.2.1.26 Check abrasion of bearing, bearing should keep clean and its vent hole should be
smooth
1.4.2.1.27 Sample from bearing oil bath to confirm metal content
1.4.2.1.28 Check whether exterior insulation has damage or not, repair it if necessary
1.4.2.1.29 Turn rotors manually, check whether rotating has noise and part abrasion or not
1.4.2.2 Clearance Regulation and Replacement of Upper and Lower Radial Sealing Piece
Check corrosion or abrasion of self-lock, nail, sealing gasket and pressing plate of sealing
device, replace them in time if necessary; it should be replaced if abrasion of sealing gasket
exceeds 1/3.
1.4.2.2.1 Find a complete main pathway plate and suspend out its corresponding 2 nd ring, 6th ring
and 10th ring hot end heat transferring elements in sector area, put them on prearranged frame
stably and reliably.
1.4.2.2.2 Install new radial sealing piece (or regulate old sealing piece) on the main pathway plate,
press it to lowest position, screw down bolts after all connections are regulated to be smooth. It is
divided into five (5) aprts from rotor center sleeve to outer edge, such as R11500mm, R2
2300mm, R34000mm, R45750mm and R57400mm; Mark at corresponding points.
1.4.2.2.3 Turn it for 360o, measure the clearances between 5 points on the sealing piece and 3
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sector plates; measure 3 points (one point at two sides of sector plate and in the middle
respectively) at each sector plate and record it well.
Note: this kind of regulation for staff guage costs much work and time, but it can avoid
clearance error due to irregular abrasion of sector plate.
1.4.2.2.4 Find out minimum axial clearance under sector plate of these 5 points, make a table and
record it. Compare with actual reuiqred clearance value and set staff guage. During installation of
staff guage, the staff guage should be in level. Upper radial clearance value: 910
68 46 24 12; lower radial clearance value: 12
510 1015 2025 3035.
2.4.2.2.5 Take this staff guage as benchmark, turn it to regulate every radial sealing piece to make
axial clearance meet requirement.
1.4.2.3 Clearance Regulation and Replacement of Axial Sealing Piece
1.4.2.3.1 Open axial valve at gas side and cut a manhole on rotor at the same time.
1.4.2.3.2 Draw out all heat accumulation components in cut hole at upper secton gas side
1.4.2.3.3 Turn gear for one circle, check sealing piece, measure rotor ellipse degree and find out
the maximum point; make a table and record them.
1.4.2.3.4 Install new axial sealing piece on the maximum point pathway plate, press it to lowest
position, and screw down bolts after all connections are regulated to be smooth. Divide sealing
piece into three points in length. Turn gear for one curcle, measure radial clearance with three arc
plate, measure three points (one point at two sides of arc plate and in the middle respectively)
under each arc plate for each point; make a table and record it well.
1.4.2.3.5 Find out minimum radial clearance under arc plate of these 3 points, make a table and
record it. Compare with actual required clearance value to set staff guage, staff guage must be in
level. Rotor ellipse degree should be no bigger than 3mm. Rotor axial clearance regulation value:
upper section 120; lower section 810.
1.4.2.3.6 Take staff guage as benchmark, turn gear to regulate every axial sealing piece to make
radial clearance meet requirement.
1.4.2.4 Clearance Regulation and Replacement of Upper and Lower Outer Edge
Circumferential Direction Sealing Piece
1.4.2.4.1 Dismantle all circumferential direction sealing pieces with abrasion and serious distortion;
put pressing plates at corresponding positions according to serial number.
1.4.2.4.2 Measure radial shake and axial shake of upper and lower circumferential direction
sealing angle steel at axial valve. The point that each pathway plate faces to angle steel is
measuring point, totally 48 points. Make a table and record it well.
1.4.2.4.3 Find out maximum point of radial shak of upper circumferential direction angle steel and
maximum point of axial shak of lower circumferential direction angle steel according to measured
data; take cords well. Upper and lower circumferential direction sealing structure type is as
following:
English
1 Fig.1 upper circumferential sealing
Sealing clearance
Jointing
Shell
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Outer edge angle
2 Fig.2 lower circumferential sealing
Outer edge angle clearance
Sealing clearance
Bolt fixing
Sheel
2
1.4.2.4.4 Set staff gauge according to comparation of found two pints and actual required
clearance. Upper circumferential direction sealing clearance regulation value: 3035mm; lower
circumferential direction sealing clearance regulation value: 2830mm.
1.4.2.4.5 Take staff gauge as benchmark, turn gear to regulate every circumferential direction
sealing piece to make its circumferential direction clearance meet requirement.
1.4.2.5 Clearance Regulation of Rotor Center Sleeve Upper and Lower Sealing
1.4.2.5.1 Clearance Regulation of Upper and Lower Inner Edge Circumferential Sealing
All top and bottom inner edge circumferential direction sealing strip should be in line with top
and bottom radial sealing piece.
Clearance between center sleeve upper sealing piece and sector plate is 9-10mm; clearance
between lower sealing piece and sector plate is 1-2mm.
1.4.2.5.2 Clearance Regulation of top & bottom center sleeve sealing and rotor shaft
Inner side sealing consists of two 1.6mm thick Corten steel rings. Low carbon supporting rings
fixes between the two rings, which is directly installed on sector plate. Rotor shaft clearance is
1mm, sealing pressing flange should be dismantled firsly during check. For the convenience of
replacement, inner side sealing is installed in two sections.
Outer sealing is gland packing stuffing. Supporting plate of stuffing seat is fixed on reinforced
plate of sector plate and gland packing stuffing is non-asbestos graphite special gland packing,
heat resistant temperature of which is no lower than 500. It is divided into three layers with
section dimension of 15mm15mm.
1.4.2.5.3 A slot pipeline leading to gas side is set between inner & outer side sealing of center
sleeve, air anf dust between two sides can be blowed out through negative pressure at gas side.
Foreing materials in inner & outer side sealing space should be cleaned during overhaul to ensure
smoothness of slot pipeline.
1.4.2.6 Application Method of Air Preheater Sealing Clearance Measuring Instrument
Application of measuring instrument is to validate hot state sealing clearance to confirm
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relative position between rotor and sector plate and rotor deflection under hot state, and to
regulate cold state clearance again or regulate rotor position in advance according to the said
clearance.
1.4.2.6.1 Measuring point of measuring instrument lies at outside of bottom sector plate, screw off
detection points thread block before measuring.
1.4.2.6.2 Loosen bolt on measuring device, extend prober of measuring device a certain length,
screw down the bolt and lock knurled nut of measuring device tightly.
1.4.2.6.3 Insert measuring device into detection point of sector plate, make sure that prober and
inner surface of sector plate are in line.
1.4.2.6.4 Make a piece of radial sealing piece face to detection point, screw measuring device
carefully until it touches sealing piece, and then measure the distance between knurled rings.
Make sure that rotor has turned one circle before screwing on prober.
1.4.2.6.5 Record sealing clearances of all detection points, take out fine powder and reinstall
thread block.
1.4.2.6.6 Notes during application:
When measuring hot state sealing clearance with measuring device, operators must wear
protection clothes to avoid burn, it is prohibited to touch hot gas directly, pay attention to protect
eyes.
Be careful when measuring clearance with prober, it may damage sealing piece if prober
insets too deep.
For rightly compare cold state clearance and hot state measured clearance, original positions
of prober should be in consistent.
1.4.2.7 Drawing Out and Reinstalling of Heat Exchanger Element Box
1.4.2.7.1 Hot section heat transferring element overhaul
1.4.2.7.1.1 Install beam on center line of top gas duct and install flying rings on beam.
1.4.2.7.1.2 Open manhole on top gas duct for the convenience of rotor entering into the top.
1.4.2.7.1.3 Turn rotor with hand-driven device installed on extended bearing of main motor or
standby motor until a sector of rotor lies directly under beam or lifting point.
1.4.2.7.1.4 Dismantle corresponding radial sealing device of the top.
1.4.2.7.1.5 Dismantle outside element boxes from rotor circumference, lift rotor away firstly before
dismantling, put it at designated location through overhaul door.
1.4.2.7.1.6 Turn the rotor and repeat above two steps, demount element boxes in sequence and
mark with numbers, avoid wounding person when turning rotor.
1.4.2.7.1.7 If there is no new element box at site, it needs to take out all element boxes and empty
load of the rotor; element boxes in all sectors should be taken out in sequence and symmetrically
to avoid unbalancing load of the rotor.
1.4.2.7.1.8 Check the drawn out element boxes, it is reuiqred that there is no ash block, dirty or
rust in through-flow area between wave plate and positioning plate; its abrasion should be lower
than 1/2. Transverse error of element box outline and rotor chamber is lower than 2mm and
longitudinal error should be lower than 1/2.
1.4.2.7.1.9 Check that pathway plate welding line is smooth and welding crater height does not
exceed 5mm.
1.4.2.7.1.10 Notices:
1.4.2.7.1.10.1 Seal the chambers that do not work and in which work are completed with frame
plates.
1.4.2.7.1.10.2 All pipes under 44m expansion joints are sealed to avoid blocking gas duct and
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wounding person.
1.4.2.7.1.10.3 Walking and standing are prohibited under lifted elements during lifting and
installing heat transferring elements.
1.4.2.7.1.10.4 Turning gear only can be turned after communication is well done, supervisor also
should be designated.
1.4.2.7.1.10.5 When drawing out and reinstalling hot end heat transferring elements, it should be
done symmetrically to avoid damaging equipments due to rotor inclination.
1.4.2.7.1.11 the standard of middle temperature end positioning is: middle temperature end upper
edge is 1000mm away from pathway plate upper edge; if it is bigger than 1000mm; it shows it
wasnt installed in right position.
1.4.2.7.1.12 Check whether specification and dimension of new heat transferring element comply
with corresponding dimension of chamber or not. During reinstalling, lift and put in elements into
boxes through overhaul door and then lower them into chamber. Standard of positioning is: hot
end upper edge and chamber plate are in the same level. If hot end upper edge is higher than
chamber plate, it shows it wasnt installed in right position.
1.4.2.7.1.13 Reinstall top radial sealing device, reinstall element overhaul door in top inlet gas duct,
check and count working personnel and tools, check and confirm no person or tool is left in air
preheater, close manhole valve on top gas duct.
1.4.2.8 Cold end heat transferring element overhaul
1.4.2.8.1 Prepare a special overhaul platform for offering a wide ground for drawing and
reinstalling, its height is the same with cold end valve.
1.4.2.8.2 Open cold section manhole valves under shell, turn rotor and make the sector of heat
transferring elements needed to be replaced face to cold section valve.
1.4.2.8.3 Dismantle bolts from cold end valve grid, take off keeper plate valve.
1.4.2.8.4 Enter from outlet (frames are built at gas side in advance, spread it with frame plates)
manhole valve at gas side of rotor lower section, jack out cold end element box in sector eara.
1.4.2.8.5 Check that cold end element wave plate is free from dirty, blocking or serious low
temperature corrosion; repair cold end supports, welding line should be smooth and connections
of supports are firm. If replacement will be done after drawing out all of them, it should be drawn
out symmetrically to avoid damaging equipment due to rotor inclination.
1.4.2.8.6 Reinstall qualified element box to corresponding sector, positioning standard of heat
transferring elements is: radial clearance between heat transferring elements is 2-4mm, install
cold end keeper plate after replacement.
1.4.2.8.7 Notice: 1. watch whether every ring is in position from lower section of gas side; 2.
during replacement, no hammer or other edge tools can be used for forceful installation; 3. when
replacing 1st ring and 2nd ring, it should be done after cutting support, welding should be firm during
reassembling.
1.4.2.8.8 Turn rotor and present a following sector area, replace continuously with above method
until all of them are replaced.
1.4.2.9 Drive Mechanism Check and Overhaul
1.4.2.9.1 Check cycle
Check running and connection state of whole drive mechanism once every three months,
especially the transverse clearance between drive mechanism resisting torque arm two sides and
resisting torque of supporting seat and connection state of resisting torque supporting seat.
Check lubricating oil vent plugs and oil levels of speed reducer box once per three months.
1.4.2.9.2 Contact with electric team to dismantle main motor and put at designated position of
platform, power creel is put at safety position to avoid breaking. Do up small speed reducer box
well.
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1.4.2.9.3 When discharging oil from drive mechanism, small speed reducing box at two sides
should be discharged firstly and then the middle speed reducing box; when discharge oil in middle
speed box, asbestos plate or iron piece should be used to make a guide groove, which introduces
oil into oil pot. When oil reaches to 2/3 of the pot, screw down oil plug. Oil discharging should be
repeated.
1.4.2.9.4 Use 100500kgf torque spanner to loosen top lock plate bolts, which is M1680 and is
totally 20 pieces.
1.4.2.9.5 During part dismantling for check of drive mechanism, A. firstly suspend speed reducing
box at big worm side with chain block and use steel plate to support speed reducing box at the
same time, see as in following. B. when loosening bolts of flanges (M3650, six pieces in total),
pay attention to gaskets on flange. C. suspend the other half shell with chain block, flying rings of
M2450 should be adopted for suspending points, two person hold the shell to avoid wound big
worm wheel.
English
Reduce
Support
Supporting point
Supporting point figure
When dismantle and check drive mechanism, A. prop up middle of joint face slot of speed
reducing box with two (2) 5T jack, jack should be rightly applied and energize evenly. B. Put the
lifted drive mechanism at safety position and spread crosstie under it, fix the drive mechanism
firmly. C. When lifting big worm wheel, steel wire rope with protection sleeve should be used to
avoid damaging copper teeth due to pressing.
1.4.2.9.6 Check teeth working face of big worm and big worm wheel, small worm and small worm
wheel; it includes following conditions:
(a) Normal contact

Check method is to spread a thin red lead powder on teeth surface of gear wheel, turn gear
wheel as per working direction and then a color print is left on teeth surface of the other gear wheel.
If big worm and big worm wheel do not contact normally, upper and lower end cover gasket of big
worm wheel should be regulated; if small worm and small worm wheel do not contact normally,
clearance between big worm and left & right end cover should be regulated. Check orientation
condition of copper teeth ring and hub, their relative displacement should not exceed 2mm.
1.4.2.9.7 Clean all parts with kerosene, check that two boxes of speed reducing box should be free
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from crack; under condition of not screwing down bolts, 0.05mm feeler gauge should not be able
to insert in-between the two boxes, otherwise it should be grinded. There should be no transverse
groove penetrating inside and outside on joint face of speed reducing box.
1.4.2.9.8 Check abrasion condition of nylon wheel-set in two small speed reducing boxes; it should
be replaced if part abrasion of nylon wheel-set hole (aperture is16) exceeds 3mm. And record it
well.
1.4.2.9.9 Check that bearing quality and clearance should comply with application requirements.
And record it well.
1.4.2.9.10 Replace framework oil sealing 250*280*15, check that new oil sealing is free from
dilapidation and aging before assembling. It can only be used after confirming it is qualified.
1.4.2.9.11 during reinstalling, 0.10-0.15mm clearance should be left between bearing outer ring
and upper & lower end cover and regulation gasket should be used for regulation. Record related
data. 587 or 703 glue should be plastered on junction surfaces of speed reducing box, glue should
be plastered evenly and not too thick, no filling stuffing should be added on junction surface. After
assembling speed reducing box, turn its bearing manually to test its agility. After confirming that
there is no problem for manual turning, put it in right position as a whole, install lock plate well,
even force for every bolt for screwing down is 250kgf. Fill oil into speed reducing tank to oil level
line.
1.4.2.10 Lower Bearing Check and Maintenance
1.4.2.10.1 Demount radial sealing pieces in sector area of three sector plate, 12 pieces in total.
The dismantled radial sealing pieces must be in consistent with sector area of upper sector plate.
Leave enough clearance for propping up rotor.
1.4.2.10.2 Open oil discharging valve to discharge lubricating oil completely in bearing tank. There
are about 105L oil in lower bearing tank. Because lubricating oil viscidity is high, it is better to
discharge oil when oil temperature is relative high.
1.4.2.10.3 Prop rotor of air preheater up with special propping up tools. Dismantle fixing bolts of
bearing box, screw and take out filler between lower bearing box and beam, draw bearing box out
and put it on prearranged place. Take off upper cover of bearing box. Rub the oil in oil tank with
fingers to feel oil quality before cleaning bearing, watch whether there is scrap iron or other
impurities in oil or not. Record it well. Check bearing inner ring, outer ring, roller, retaining frame
and record it well.
1.4.2.10.4 Technical process, scheme and sequence for replacing bearing are as following:
1.4.2.10.4.1 Inspect, appraise old bearing inner ring, rest complete roller, pole and frame, rolling
track, force bearing sleeve, inner ring sleeve and lower bearing box; analyze bearing dilapidation
fatherly. Record the details before dismantling.
1.4.2.10.4.2 Take out force bearing sleeve at upper section of bearing, measures and record the
cooperation dimension and cooperation clearance of force bearing sleeve and inner ring sleeve
(800n6, cooperation tensioning stress is 0.08-0.13mm) .
1.4.2.10.4.3 Draw out inner ring protection sleeve at upper section of bearing from bearing inner
ring, measure and record the cooperation dimension and cooperation clearance of force bearing
sleeve and inner ring sleeve.
1.4.2.10.4.4 Take rolling column and rolling track out from lower bearing box, measure and record
the cooperation dimension and cooperation clearance of outer rolling track and lower bearing box.
1.4.2.10.4.5 Inspect, appraise new bearing inner ring, rolling column, pole and frame, rolling track
and lower bearing box; record the details before installation. Make sure that there is no dilapidation
to above parts.
1.4.2.10.4.6 Measure and record outer rolling data of new bearing, when the cooperation
clearance between it and lower bearing box complies with requirement, install outer rolling track
into lower bearing box (1360M7 cooperation tightening stress is 0.060.17mm).
1.4.2.10.4.7 Measure and record data of new bearing inner ring and inner ring protection sleeve,
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when the cooperation clearance between them complies with requirement, install inner protection
sleeve and bearing inner ring together with press.
1.4.2.10.4.8 Measure and record data of force bearing sleeve and new inner ring protection sleeve,
when cooperation clearance between them complies with requirement, process a special pressing
pad of900100, install subassemblies of force bearing sleeve, inner ring protection sleeve and
bearing inner ring together with 500T press. If heating method is adopted for assembling, bearing
heating up temperature should not exceed 100. 0.05mm feeler gauge can not be inserted into
junction surfaces after assembling.
1.4.2.10.4.9 Lift and lay down subassemblies of force bearing sleeve, inner ring protection sleeve
and bearing inner ring into lower bearing tank, test it by turning and record the testing results.
1.4.2.10.4.10 Lift out subassemblies, watch and record cooperation condition of rolling column and
rolling track. If they do not contact completely during cooperation, it is deemed as unqualified.
1.4.2.10.4.11 Vinylon Rope must be used to suspend and install bearing subassemblies during
assembling.
1.4.2.10.4.12 Protract structure diagram again and mark the detail dimension of all parts and their
cooperation tolerance. Reinstall lower bearing in reversal sequence of 2, 3, 10 and 5. Clean it to
avoid scrap iron or other impurities dropping into bearing box. Pull bearing box together with
supporting plate to right position, install orientation bolts well. Screw off jack lock cap, open four (4)
manual valves of oil pipeline header, regulate oil pump pressure relief valve, relief pressure while
loosen jack lock cap, and then lay down rotor slowly. Fill oil into bearing box, turn rotor of the
preheater manually and listen to bearing sound.
1.4.2.11 Top Guide Bearing Overhaul
1.4.2.11.1 Demount rotor drive system
1.4.2.11.2 Arranging supporting pieces must ensure rotor keeps in vertical position
1.4.2.11.3 Discharge lubricating oil in top bearing
1.4.2.11.4 Loosen fastening disc on bell flange according to drawing.
1.4.2.11.5 Demount top cover plate after demounting six slot bolts.
1.4.2.11.6 Use demounting hole on bearing bell installation flange to lift and move installation
flange together with guide bearing upwards and vertically.
1.4.2.11.7 Demount guide bearing from bell flange after demounting six slot bolts and bearing
fixing ring.
1.4.2.11.8 Install guide bearing on bell flange, reinstall bearing fixing ring and six slot bolts
1.4.2.11.9 Reinstall top cover plate and fastening disc on bell flange
1.4.2.11.10 Dismantle temporary supporting pieces arranged between rotor and rotor shell
1.4.2.11.11 Fill lubricating oil into top bearing
1.4.2.11.12 Reinstall rotor drive system
1.4.2.11.13 If it is necessary to replace top guide bearing, top and bottom stuffing and sealing
fittings should also be replaced.
1.4.2.11.14 Ensure that right position between bearing top and bearing box top is 162mm.
1.4.2.11.15 Ensure that installation distance between bearing sleeve shoulder and bearing box top
cover plate is 34.4mm.
1.4.2.12 Soot Blower Overhaul
1.4.2.12.1 Cut off power supply of main motor and standby motor
1.4.2.12.2 Cut off steam, water and power source of soot blower
1.4.2.12.3 Dismantle steam and water inlet flange from steam supplying pipe
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1.4.2.12.4 Dismantle power connections on terminal box
1.4.2.12.5 Use proper flying ring to support air preheater exterior to avoid dropping
1.4.2.12.6 Dismantle installation flange on soot blower of interface box
1.4.2.12.7 Demount soot blower from fixed supporting frame
1.4.2.12.8 Soot blower interface box should be realigned on air preheater shell to ensure right
reassembling of soot blower
1.4.2.12.9 Install soot blower on fixed supporting frame
1.4.2.12.10 Reinstall installation flanges of soot blower on interface box
1.4.2.12.11 Dismantle steam and water inlet flanges from steam supplying pipe
1.4.2.12.12 Reinstall steam, water and power source of soot blower
1.4.2.12.13 Reinstall power supply connection on terminal box
To avoid ash accumulation and ensure smoothness of heating surface, soot blowers should
be in operation, especially during starting period. Soot blower is installed at cold end gas outlet of
air preheater.
Soot blowing medium pressure and soot blowing times are strictly controlled, exceeding
recommended maximum pressure or soot blowing times exceeding recommended value may
shorten life of heating surface.
When steam is working as soot blowing medium, pipeline drainage water devices before
steam enters into air preheater should be installed near soot blower, steam flow enters into soot
blower upwards to avoid water entering into air preheater.
Recommended steam parameters at soot blower nozzle of air preheater are shown in table 1
Soot Blowing Steam Parameter.
Table 1 Soot Blowing Steam Parameter
Pressure Temperature Enthalpy Overheated
Kpa(PSIG) F h F
896130 310590 1321 131235
1103160 332630 1339 144259
1379200 352665 1355 153277
1517220 362683 1364 160288
1723250 376708 1375 168302

Recommended value and maximum value of soot blowing pressure is offered in table 2 Soot
Blowing Design Requirement
Table 2 Soot Blowing Design Requirement
Nozzle maximum Recommended Recommended Maximum soot Maximum
diameter soot blowing soot blowing blowing pressure soot blowing
inch(mm) pressure PSIG pressure KPa pressure KPa
PSIG
0.63(16) 150 1034 200 1378
If it fuels oil during boiler start up, soot blowing medium is steam, minimum pressure is
1034KPa (150Psig). Soot blowing medium is air, minimum pressure is 620Kpa(90Psig). During
start up, soot blowers must be put into operation, recommenced soot blowing frequency is once
per 4 hours; when unit is normal operation, soot blow once per 8 hours.
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1.4.2.13 Rotor Speed-lost Alarm Detector Overhaul
1.4.2.13.1 Cut off power supply of rotor speed-lost alarm device;
1.4.2.13.2 Screw off fixing bolts of rotor speed-lost alarm device on protection cover of drive
device;
1.4.2.13.3 Open junction box locally, dismantle connections of speed-lost alarm device;
1.4.2.13.4 Reinstalling process of detector is just reverse to above steps, pay attention to drive
shaft end of rotor and regulates relative position of detector end.
1.4.2.14 Fire Detector Overhaul
Thermocouple is installed in fire detector, thus it should be carefully operated. If it is
necessary to dismantle fire detector during boiler operation, personnel at site must wear protection
suits and keep away from installation hole to avoid burning skin by high temperature air flow. Thus,
compressed air should be used for sealing during dismantling and installation. All installation
sleeve pipes of detectors should be welded on top structure, which is to ensure installation angle
of detector and distance between detector and heat exchanging element and also has predigested
installation procedure.
1.4.2.14.1 Dismantle fire detector
1.4.2.14.1.1 Cut off power supply of detector and dismantle connections in junction box at detector
end;
1.4.2.14.1.2 Open compressed air valve on sleeve pipe, ensure that compressed air flows into
detector sleeve pipe;
1.4.2.14.1.3 Dismantle fastener of detector flange;
1.4.2.14.1.4 Draw out detector from sleeve pipe, do not damage thermocouple at front end of
detector; if thermocouple is not going to be installed immediately, cover plate should be applied to
block sleeve pipe.
1.4.2.14.2 Clean and check detector
1.4.2.14.2.1 Clean sediments on detector pipe with wire brush;
1.4.2.14.2.2 Clean thermocouple end of detector with hair brush and weak washing soda; clean it
with water and then dry it;
1.4.2.14.2.3 Check whether thermocouple of detector has corrosion and dilapidation or not;
1.4.2.14.2.4 Open circuit check: check resistance of thermocouple through connection end of
detector; if it exceeds 30, it shows that thermocouple has problem;
1.4.2.14.2.5 Check insulation resistance of thermocouple; if resistance is low, it shows that
thermocouple insulation is damaged.
1.4.2.14.3 Reinstall detector
1.4.2.14.3.1 Before dismantling cover plate of sleeve pipe flange, make sure that air valve is open
and there is compressed air flowing through it.
1.4.2.14.3.2 Install heat insulation washer between detector flange and sleeve pipe flange;
1.4.2.14.3.3 Put detector in right position and fix it, connect connections in junction box.
1.4.2.14.3.4 Close compressed air valves after installation of detector.
1.4.2.14.3.5 Start local cabinet and recover it to be normal.
1.4.2.15 Air Leakage Rate and Air Leakage Coefficient of Air Preheater
Air Leakage rate and air leakage coefficient are important indexes for judging air preheater
performance.
1.4.2.15.1 Air leakage rate means rate of air amount leaking into gas side and entered gas
amount.
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Air leakage rate is calculated as per following formula:
L(%)=(E"- E')/ E'100%
In the formula: E' gas amount of air preheater inlet kg/s
E" gas amount of air preheater outlet kg/s
1.4.2.15.2 Air leakage coefficient means difference of excessive air coefficient of outlet gas and
excessive air coefficient of inlet gas.
Air leakage coefficient calculation formula:
=
In the formula: ----- Air leakage coefficient
----- excessive air coefficient of outlet gas
----- excessive air coefficient of inlet gas
1.4.2.15.3 Conversion of air leakage rate and air leakage coefficient
L=( )/ 90
Excessive air coefficient calculation formula:
21/(21O2)
That is: calculating by detecting oxygen amount at outlet and inlet oxygen at gas side of
preheater.
1.4.2.16 Heat transferring element box installation of semi-module air preheater
A. Earth rotor before welding rotor to avoid burning bearing of air preheater.
B. Open element box installing and dismantling valve on rotor shell.
C. Fix element box installing and dismantling platform at a height required by element box to
be installed.
D. Turn rotor to make opening on element box and element box installing and dismantling
mouth on rotor shell shield be in the same line.
E. Lift element box. Lift one element box once and put it on element box installing and
dismantling platform (there can be only one element box on the platform).
F. Start from the most inside element box (An box designed to be A on element box general
diagram) for the installation of new element boxes. A box must be inserted to most front end of
rotor compartment to make element box length edge cling middle comparting plate of sector
compartment. Force should be done along cold end side centerline of element box frame evenly to
avoid blocking in bar frame.
G. Refer to rotor installation diagram, only when A box is in right position, which can ensure
that other element boxes can be rightly installed at radial position.
H. Install the rest element boxes into compartment (see as in figure: Element Box
Arrangement and Installation). Make sure that front end of element box touches end plate of
previous element box, or its two sides touch with comparting plate.
After the most outside element box is at right position, install axial sealing plate strip and
element box circumferential sealing; see as in Element Box Arrangement and Installation
Diagram.
J. Turn rotor to the next empty compartment, repeat steps from D to I.
K. Repeat steps from D to J until element boxes in this layer are completely installed.
L. Regulate element box installing and dismantling platform to height of next layer and repeat
steps from D to K.
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M. Repeat steps from C to L until semi-module rotor compartment is fully installed with
element boxes.
1.4.2.17 Rotor module sector compartment element box demounting
During actual operation, any method can be used for taking out element box from rotor
compartment only if not destroying element box or rotor compartment structure. Following is
recommended element demounting process of semi-module air preheater:
A. Earth rotor before welding rotor to avoid burning bearing of air preheater.
B. Open element box installing and dismantling valve on rotor shell (see as in Rotor Shell
Assembling Diagram).
C. Fix element box installing and dismantling platform at a height required by element box to
be installed.
D. Turn rotor to make opening on element box and element box installing and dismantling
mouth on rotor shell shield be in the same line.
E. Cut welding line between rotor comparting plate and axial sealing plate strip, cut welding
line between rotor shell and element box circumferential sealing angle steel, cut welding between
element box and element box circumferential sealing plate strip.
F. Hook cold end plate of element box with hook and take out element box. Repeat this
process and draw out all element boxes from compartment.
DU3 FNC
(Fig 2) Air preheater heat transferring element plate type
English
DU3 DU3 type heat transferring element
187
FNC FNC type heat transferring element
G. Turn rotor to the next sector compartment, repeat steps from C to F.

H. Repeat steps from C to G until all the element boxes in this layer have been taken out.
I. Regulate element box dismantling and installing platform to height of the next payer, repeat
steps from C to H.
J. Repeat steps from C to I until all the element boxes are taken out.
1.4.2.18 Cleaning device
Fixed water cleaning and fire fighting device
(Fig 3) Fixed water cleaning device

If accumulated ash on heating surface of Ljunstorm air preheater can not been removed by
soot blowing device, it must be cleaned.
Fixed cleaning water pipes should be installed for air preheater, one is arranged at hot end
gas inlet and one is arranged at cold end gas outlet.
Water cleaning for air preheater should be done during boiler shutdown, thus heating surface
can be checked periodically by naked eyes to confirm cleaning effect and when to clean. Cleaning
times and cleaning time depends on different devices and experience. Heating surface cleaning
should be done according to following procedures:
A Sufficient device should be offered to collect and discharge cleaning water discharged
from air preheater. Ensure that drainage system has sufficient gradient to avoid subsidence of
accumulated ash in drainage water system. Check water discharging funnel and water discharging
system periodically to ensure that they are not blocked.
B Check water discharging funnels before cleaning and make sure that there is no block.
C During cleaning, in order to limit water amount brought to air side of air preheater to be
minimum, decrease rotating speed of rotor to 1/4 of main drive rotating speed (maximum rotating
speed) with frequency conversion.
D Generally accumulated ash can be dissolved easier in hot water, cleaning water can be
heated up, but it is not forceful due to that required water amount is great.
E Clean continuously until all the heating surfaces are clean. It must be checked completely,
because accumulated ash left after cleaning would coagulate on heat transferring elements, and
these accumulated ash will be undissolvable and hard to be removed after putting preheater into
operation.
F Make sure that water supply has been completely closed after cleaning. Sewage after
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cleaning is discharged from neighboring pipeline and drainage water pipeline, preheater rotor and
heating surface should be dried immediately after cleaning air preheater.
Generally, we think it is not necessary to clean the heating surfaces with chemical, but some
operators chooses buck (water solution of NaOH) for cleaning heating surface. If this method is
adopted for heating surface cleaning, operators can do it according following steps:
Clean heating surface with water as per said processes.
NaOH solution should be supplied by a separate system. Proper equipments should be
supplied to discharge and collect NaOH solution from air preheater. Make sure water discharging
pipeline should be with sufficient to avoid sediment of impurities in pipeline. Check water
discharging funnels and pipelines periodically to avoid blocking.
Before buck cleaning, check water discharging funnel to ensure that hatch is not blocked and
to avoid wetting air preheater due to water that can not be discharged after cleaning.
Decrease rotor rotating speed to reduce alkali solution that brought to the other side of air
preheater.
PH value range of NaOH solution for cleaning heating surface should be within 9.5-10.5.
Continue to clean heating surface until PH value of NaOH solution left from air preheater
reaches to 9.5 or higher.
After alkali cleaning, make sure that buck supply has been completely closed. Sewage after
cleaning is discharged from neighboring pipeline and drainage water pipeline, preheater rotor and
heating surface should be dry before putting air preheater into operation.
It is not recommended to have Isolation cleaning for one preheater due to following reasons:
A Isolation baffle can be closed strictly or completely isolated, which means that check can
not be done well to confirm when to finish cleaning, incomplete cleaning is worsen than no
cleaning, because when air preheater is put into operation again, unclean part will be sinterred on
heating surface, which makes it very difficult for the next cleaning.
B To shorten water cleaning time may result in incomplete cleaning.
C No matter under any condition, air and gas are not allowed to flow through air preheater;
when hot heat transferring element is enclosure in cold cleaning water, the temperature changing
will shorten life of heat transferring element.
The only acceptable working condition for cleaning air preheater is boiler shutdown state,
which is planned shutdown for check or maintaining. During this time, cleaning can be done and
cleaned heating surface can be completely checked. Heating surface checking method is: take out
several elements box from every layer randomly and then dismantle them, check them piece by
piece to ensure that all accumulated ash has been removed.
Storage of elements in element box
If it needs a long time before air preheater installation or running, it is suggested that antirust
oil should be plastered on heating surface, heat transferring elements in operation should not be
plastered with antirust oil. When heating surface is clean, it is not necessary to clean it before
cleaning.
1.4.2.19 Supporting bearing
Air preheater rotor is supported on thrust radial roller bearing 294/710EF through center sleeve
and axle end device, supporting bearing should install on joist frame at cold end.
At upper section of air preheater, rotor is fixed on guide axle end of center sleeve through
bolts; guided by double-row self-aligning spherical roller bearing, guide bearing is fixed on hot end
center joist frame.
Supporting bearing and guide bearing adopt oil bath lubrication.
See as recommended lubricating oil type and grade of bearing in lubrication part.
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1.4.3 33.5-VI (T)-2333-QMR type air preheater rotor shaft dismantling process
1.4.3.1 Brief introduction:
A When it is necessary to dismantle, supporting bearing and guide bearing must be
dismantled and assembled firstly, other parts can only be dismantled after assembling of said
bearings, which makes bearing and rotor always align.
B Necessary tools, detergent and lubricating oil must be prepared before dismantling bearing,
read shop drawings and instructions completely.
C All parts should be marked during dismantling to avoid mistake.
1.4.3.2 Rotor supporting bearing dismantling process
A Prepare overhaul ground and space under supporting bearing
B Lift hot end sector plate to maximum position
C Discharge oil in bearing tank
D Dismantle oil pipe, cooling water pipe, temperature sensor and oil scale pipe for respecting
overhaul; add pipe block at pipe end to prevent dust and impurities.
E Demount waterproof cover and bearing tank cover (interface should be marked).
F Selection parameter of hydraulic jack and recommended jacking process refer to this
manual book, recommended rotor jacking process is as following: demount supporting load
according to this process, dismantle overhaul hole cover of static sealing sleeve at cold end firstly,
put two hydraulic jacks at air side and gas side respectively, jack round steel or square steel on
lower end plate of rotor (see the detailed application of hydraulic jack in its manual book); after propping
up rotor, fill up round steel or square steel between rotor lower end plate and cold end center truss
frame to avoid accident.
G Dismantle packing block at bottom of supporting bearing
H Move bearing box, bearing and connection seat to end of cold end center truss frame as a
whole and then transport them to bearing overhaul platform.
I Dismantle bearing inner ring and roller.
J Take supporting bearing outer ring from bearing box.
K Replace roller bearing of annular contact thrust ball surface according to supporting bearing
drawings and installation, operation instruction.
1.4.3.3 Reinstalling
Reinstall supporting bearing according to reverse procedures of said procedures in 3.2 and
following should be bear in mind:
A Before reinstalling bearing, clean inner surface of bearing box and bearing completely with
pure oil, avoid dust, rain water and impurities entering into bearing box.
B When bearing box is in position and bear rotor weight, do not impact bearing.
C Put precision leveler onto bearing box to check level degree of bearing box; regulate
packing block if necessary.
D After rotor weight drops on supporting bearing, remove oil pressure jack and reinstall arc
pad of static sealing sleeve that dismantled for jacking rotor.
E The cooperation between connection seat of supporting bearing and bearing inner ring,
bearing outer ring and bearing box, which if needs hot press, #90 turbine oil should be used with
temperature of about 80 but not exceeding 120.
F Clean with oil after installation.
1.4.3.4 Recommended rotor jacking procedure.
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(Fig.4) Supporting bearing
English
Jack
Supporting bearing
A Dismantle bolts from static sealing sleeve before dismantling water-proof cover and
bearing box cover, take off demountable parts for getting close to lower end plate of rotor center
sleeve; clean the accumulated ash at this time.
B Put oil pressure jack on cold end truss frame, as its position in cold end connection plate
general drawing.
C Set up oil pressure jack until they touch with their rotor center sleeve.
D Measure dimension between rotor sleeve and supporting fittings of oil pressure jack, the
height of four 100mm round steel or 100100mm square steel is the measured dimension said
above, the round steel or square steel is installed near jack to support rotor.
For thrisection air preheater, only three supporting blocks are needed. After checking or
replacing supporting bearing, oil pressure jack remains at original position for helping to take out
supporting block.
E Check or replace supporting bearing according to regulations said above.
1.4.4. Guide bearing
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(Fig. 5) Guide bearing
1.4.4.1 Preparation before guide bearing installation
A Nails should be drawn when opening bearing packing box to avoid damaging bearing in
box.
B All cloth for cleaning and using should be checked whether there is foreign material that
may cause nick or not. Finger ring should be taken off before cleaning.
C Guide bearing (especially bearing box) installation should be in consistent with general
drawing.
D Clean fixing sleeve completely, remove all oil beads and grease from roller bearing and
bearing box, clean gibbous parts (iron file is prohibited) on surface and burr with flat scraper.
E Lubricate screw threads part and lower section of bolts with lubricant.
F Seal joint part of sealing washer with sealing glue.
G Protection measures should be taken for guide bearing and all parts until installation to
prevent from damage and pollution.
1.4.4.2 Guide bearing dismantling and installation
A For the convenience of installing, dismantling and replacing bearing, chain wheel crane or
similar equipment should be installed directly above bearing.
B Move away center drive mechanism and coupling
C Demount bearing box cover.
D Discharge oil from bearing box
E Loosen expansion sleeve and take off tightening sleeve, bearing and lock nuts.
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F Now, check the bearing, demount bearing from tightening sleeve if necessary to replace.
Thus, lock plate should be firstly demounted, retreat lock nut for about 4.8mm, connect a tube to
screw hole at end of tightening sleeve. Loosen cooperation between bearing and tightening sleeve
with hydraulic pressure.
G Once bearing is loosened, take off lock nut and demount bearing from tightening sleeve.
H Measure and record radial clearance before installing new bearing on tightening sleeve. Put
bearing on a plane vertically to make outer ring and inner ring parallel, measure radial clearance
between top roller and outer ring with feeler gauge.
I Press new bearing into tightening sleeve with lock nut; if necessary, decrease the measured
radial clearance value with oil pump pressure until original radial clearance decreases by 0.18mm.
J Press lock nuts with lock plate tightly.
K Light oil should be plastered on cooperation surface of expansion sleeve and axle end,
tightening sleeve and axle end and cooperation surface of bearing inner ring and tightening
sleeve.
L Fix tightening sleeve on axle end with bolts on expansion sleeve, screw down M20 bolts
evenly, screwing down torque is 470N.m.
M Fill bearing box to maximum level with recommended lubricating oil, oil or light grease
should be evenly plastered on inner surface above oil level and on box cover to avoid rust.
N Earth must be done for welding after bearing installation, it is absolutely prohibited that
welding current flows through bearing surface to avoid burning bearing.
Installing and dismantling of guide bearing see as in annotations in guide bearing general
diagram.
1.4.4.3 Guide Bearing Operation and Maintenance
After bearing installation, guide bearing performance should be ensured by daily check, timely
problem resolving and periodical maintaining.
Check corrosion of surface above oil level once per month.
Check oil pollution (dust, flying ash and water) once per month.
C Once oil pollution is found, oil in bearing box should be discharged completely for cleaning.
Slow running speed has no significant influence on oil temperature rise; During operation,
the reason of any abnormal temperature rise of oil should be found out immediately. The reasons
are generally as following:
Air flow space around guide bearing is limited
Oil level is too low
Oil is too fully filled
Oil is polluted
Oil viscidity is improper
E Bearing should be repaired immediately when bearing sends abnormal sound. Low oil level,
insufficient viscidity, flying ash and oil pollution may influence bearing normal operation.
F Change oil for guide bearing; Contents related to lubrication are seen in lubrication part.
This should be done once per year or according to requirement.
1.4.5. Rotor Drive Mechanism
Air preheater adopts center transmission. Center transmission device consists of one main
motor, one auxiliary motor and one air motor. Main motor connects speed reducer through
coupling, standby motor and air motor connects with speed reducer through overrunning clutch.
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Motor has three speed thresholds of high gear, slow gear and overhaul gear, among which high
gear is normal working gear and slow gear is for air preheater cleaning. During high gear, speed
reducer normal output bearing rotating speed: 0.9r/m; rotor normal rotating speed: 0.9r/m; rotor
rotating speed adopting frequency conversion slow speed threshold: 0.23r/m. Confirm high gear
and low gear before starting system (main switch of speed transversion), press Start button,
motor will start slowly, it costs 60s for the system to reach rated frequency and motor to reach
rated rotating speed. Preheater starting must adopt transducer slow starting up; power frequency
is not allowed for starting.
1.4.5.1 Check Transmission Operation
Operators check all exposed bolts whether they are loosened or not.
Operators check oil level periodically (every shift).
Drive mechanism runs normally or not.
Change oil for speed reducer that put into operation for the first time after half month, change
oil once per half year after normal running.
Note: See as detailed instruction in operation instruction and maintenance manual of the
manufacturer
(Fig.6) Center Drive Device

1.4.6 Air preheater lubrication
For ensuring long term, high efficiency operation, all parts of Ljungstorm air preheater should
be lubricated before running; after stable operation, make a feasible lubrication schedule
according to running condition and actual experience.
1.4.6.1 Lubricating oil amount
Rotor bearing, lower supports adopts spherical roller thrust bearing, which needs about 150
liters oil; guide bearing needs about 43.5 liters oil.
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Note: the offered demanding oil amount for rotor supporting bearing and guide bearing does
not include oil filled into pipeline system, all oil above values are approximation, which can be
reduced or increased according actual requirement.
1.4.6.2 Selection of lubricating oil
Selection of bearing lubrication oil depends on maximum running temperature of bearing,
which depends on lubrication and cooling system model and bearing environment temperature.
Oil bath lubrication is adopted for supporting bearing and guide bearing of air preheater. The
using lubricating oil is high temperature resistant lubricating oil with plumbum cycloparaffin
additive or pure mineral oil. Due to heavy load and low speed of rotor bearing, viscidity of
lubricating oil should be about 1000SSU to ensure bearing life.
When maximum running temperatures of supporting bearing and guide bearing are the same,
selected oil for supporting bearing can also be used fro guide bearing.
We suggest that both supporting bearing and guide bearing adopt N6801000 middle load or
high load extreme industrial gear oil. Lubrication of drive mechanism speed reducer can be seen
in related manual book from the manufacturer.
Lubricant should not be filled too fully, confirm all oil levels of bearing box, speed reducer and
motor before operation.
1.4.7. Air Preheater Sealing
1.4.7.1 Brief Itroduction of Air Preheater
Ljungstorm air preheater is a rotary heat exchanger device with converse flow of air and gas.
During heat exchanging, it trends to lose energy, which is because of air leakage to gas due to
differential pressure between air and gas. Sealing system can control and reduce air leakage to
decrease energy lose. Sealing system is designed according to the principle that rotor of air
preheater distorts when heated; it includes radial sealing, axial sealing, bypass sealing and static
sealing. Thia sealing system has offered a lot regulation values for the convenience of
maintenance.
1.4.7.2 Center Sleeve Sealing
Center sleeve sealing pieces are installed at hot and cold end of inner side of every rotor
radial isolation plate (see as in radial sealing device installation diagram), center sleeve sealing
circles hot and cold end rotor center sleeve. During operation, center sleeve sealing cling static
sealing coiling of guide and supporting end shaft encircling center sleeve in connection plate of air
preheater. Notch center sleeve sealing and fix it on inner end of radial isolation plate, no matter
radial or axial (close to or far from hot end or cold end static sealing cooling), sealing can be
regulated and welded.
Generally rotor center sleeve sealing does not need to be replaced; if it is necessary, it should
be installed between radial sealing. See as center sleeve sealing replacement in radial sealing
device installation diagram and following steps should be adopted:
A. Dismantle the current sealing fittings welded on radial isolation plate and flanges and
shovel sealing welding lines to be smooth.
B. Right sealing width should be ensured during new sealing installation, sealing at cold end is
wider than that at hot end.
C. Sealing at each end is supplied in six 60 parts, notch and fix them on inner end of radial
isolation plate. During installing rotor center sleeve sealing, make sure the clearance between the
sealing and sector sealing plate surface is 10.5mm, and make sure that clearance between
sealing and circumferential sealing surface of static sealing coiling is 1.5mm.
D. Welding should be done at center sleeve sealing connection, and only weld sealing of
flange and radial isolation plate sealing.
1.4.7.3 Radial Sealing
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Install radial sealing piece along hot end & cold end edge of every rotor radial isolation plate
(see as radial sealing device installation diagram), clearance between radial sealing piece and
sector plate is minimum during operation. Fix waist bolts holes of radial sealing piece on radial
isolation plate with bolts, sealing piece can be regulated along axial direction (close to or far away
from hot end or cold end sector plate), if these sealing pieces touch sector plates, abrasion starts;
when sealing is abraded to be insufficient for axial regulation, sealing pieces should be replaced.
See as radial sealing replacement in radial sealing device installation diagram and following steps
should be adopted:
A. Dismantle current sealing pieces and clamping slats, air cutting should be done or bolts
should be screwed off for dismantling sealing.
B. Before installing new sealing, rotor level degree should be kept within 0.4mm/m.
C. New sealing installation should be started from outer end, insert bolts with gasket into outer
& inner end bolts holes of outer sealing pieces, install radial sealing piece and fix it with nuts and
gaskets, but do not screw it down, because sealing piece may be moved out during final regulation.
Install the rest bolts and gaskets. Repeat above steps to install middle or inner side radial sealing
pieces.
D. After installing new sealing pieces on all radial isolation plates, install direction-correction
device of radial sealing, fix it on supporting channel steel with bolts, channel steel has been
welded at gas side or air side of hot & cold end connection plate with one end welded at inner side
and the other end at outer side.
E. Turn rotor to make radial sealing piece of radial isolation plate lie at edge of sector plate,
regulate inner side and outer side sealing with feeler gauge to regulated clearance (see as sealing
regulation and installation diagram) and screw down nuts. Turn rotor and make the sealing lie at
edge of every rest sector plate, check the clearance of sector plate inner side and outer side.
F. It is not necessary to regulate the sealing again if clearance variation is no bigger than
0.5mm; if clearance variation is bigger than 0.5mm, regulate clearance value according to
sealing regulation and installation diagram. Take sector plate with maximum clearance as
reference for regulation.
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(Fig. 7) Cold end radial sealing clearance table
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(Fig.8) Air preheater sealing regulation diagram
G. Turn rotor and make radial isolation plate with sealing piece turns to be under sealing
direction-correction device, sealing piece has been regulated as per sector plate. Regulate sealing
direction-correction device and make it just touch with sealing piece. Screw down radial bolts.
H. Turn rotor to make every sealing piece of radial isolation plate be under sealing
direction-correction device. Regulate sealing piece to make it just touch with direction-correction
device. Screw down radial sealing bolts.
I. After all radial sealing are regulated and fixed, dismantle sealing direction-correction device
and preserve it for future application.
1.4.7.4 Axial Sealing
Install axial sealing piece along axial edge of outer side of every rotor radial isolation plate
(see as axial sealing device installation diagram), clearance between axial sealing piece and static
axial sealing plate is minimum during operation. Fix waist bolts holes of axial sealing piece on
radial isolation plate with bolts, sealing piece can be regulated along radial direction (close to or far
away from sealing plate).
If these sealing pieces touch with axial sealing plates, abrasion starts; when sealing is
abraded to be insufficient for radial regulation, sealing pieces should be replaced. See as axial
sealing replacement in axial sealing device installation diagram and following steps should be
adopted:
A. Maintenance hole should be opened at proper position on shell of each side of main seat
frame for regulating axial sealing.
B. Before installing new sealing, rotor level degree should be kept within 0.4mm/m.
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C. Dismantle current sealing pieces and clamping slats, air cutting should be done or bolts
should be screwed off for dismantling sealing.
D. Install direction-correction device of axial sealing, fix it on supporting channel steel with
bolts, channel steel has been welded at inner side of rotor outer shell close to hot & cold end of
sealing plate.
E. Regulate sealing direction-correction device, make the distance between the device and
axial flounce maximum point of hot & cold end rotor sealing angle steel be 2 mm. Turn rotors,
confirm the point with centigrade meter and mark it.
F Install clamping strip and sealing piece and fix it with nuts and gaskets; it should not be
screwed down, sealing pieces may be moved in or out during final regulation.
G Turn rotor and make axial sealing just lie before sealing direction-correction device,
regulate sealing piece to make it just touch with sealing direction-correction device. Screw down
axial sealing bolts.
H Install other clamping strip and axial sealing pieces of other radial isolation plate. Regulate
axial sealing piece as per sealing direction-correction device.
I. After installation of all axial sealing and regulation as per sealing direction-correction device,
dismantle sealing direction-correction device and preserve it for future application.
J. Turn rotor until a radial sealing piece on radial isolation plate faces to edge of radial sealing
plate, check and regulate axial sealing plate according to regulation and installation diagram.
Measure clearance between axial sealing piece and axial sealing plate with feeler gauge at hot
and cold end, it is not necessary to regulate axial sealing plate if variation does not exceed
0.5mm; if variation exceeds 0.5mm, move in or move out axial sealing plate with regulator to get
regulated clearance. Regulator is outside of main seat frame of air preheater.
K. Turn rotor to make axial sealing lie at inlet & outlet edge of axial sealing plate, check the
clearance, if error between the clearance and regulated value exceeds 0.5mm, axial sealing
plate should be regulated to get required clearance at hot end and cold end.
L. Turn rotor to make axial sealing faces to adverse axial sealing plate, check according to
above steps, and regulate axial sealing plate if necessary.
M. After installation of axial sealing, seal the opening.
1.4.7.5 Bypass Sealing
Install axial sealing piece at outlet and inlet of air preheater along inner side of rotor shell (see
as bypass sealing device diagram). These sealing pieces are distributed in circumference at air
side and gas side of hot end and cold end of air preheater rotor outer shell. During operation, rotor
distorts clearance between hot end and cold end rotor angle steel and static bypass sealing piece
is minimum. Open waist bolts holes on bypass sealing piece and fix it on bypass sealing angle
steel with bolts. Bypass sealing piece can be regulated along axial direction (close to or far away
from cold, hot end sector sealing surface).
If these sealing pieces touch with hot end or cold end rotor angle steel, abrasion starts; when
sealing is abraded to be insufficient for radial regulation, sealing pieces should be replaced. See
as axial sealing replacement in bypass sealing device installation diagram and following steps
should be adopted:
A. Get close to bypass sealing through inner part of air preheater hot end or cold end
connection plate ga duct.
B. Current sealing pieces and clamping strips should be dismantled for replacing these
sealing. Bolts may be cut for dismantling sealing. Preserve clamping strip for application with new
sealing pieces.
C. Before installing new sealing, rotor level degree should be kept within 0.4mm/m.
D. Right sealing width should be ensured during new sealing installation, sealing at hot end is
wider than that at cold end.
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E. During installing new sealing pieces, make sure that out layer sealing piece and inner layer
sealing piece stagger, which makes notches on bending section stagger to each other.
F. Repair sealing piece and make it cling axial sealing plate and sector plate. One or more
sealing pieces may be corrected to face to bolts hole.
G. During installation of new sealing pieces, relative positions of sealing pieces and rotor
angle steel should be right to avoid deflection during operation. Regulated clearance between hot
end & cold end bypass sealing and rotor angle steel see as in sealing regulation diagram, regulate
sealing piece to regulated clearance.
H. Make sure that all bolts and lock nuts are screwed down.
1.4.7.6 Serious Sealing Abrasion
Sealing device and sealing surface of air preheater is arranged as this: under BMCR load,
design temperature can offer best control of air leakage. When temperature rises to be higher than
design temperature, design clearance between sealing and sealing surface is not enough make
up superfluous hot distortion, which may cause abrasion of sealing and sealing surface. Following
running conditions will cause serious sealing abrasion.
A. Gas & air temperature entering into air preheater exceeds design value.
B. Air going through preheater reduces. When air amount gets closes to zero, sealing
abrasion degree increases.
C. Hot standby state, there is gas & air in air preheater but no air flow, air preheater or boiler is
at hot standby.
D. Rotating speed of air preheater is lower than design value, sealing abrasion degree
increases with decreasing of rotor speed.
E. Air preheater is in operation before isolation.
Because sealing abrasion has increased clearance between sealing and sealing surface and
it has increased air leakage amount during normal operation under BMCR. During sealing
abrasion, if sealing contacting resistance is big enough, drive motor of air preheater may be
overloaded. Following steps should be adopted to reduce possibility of sealing serious abrasion
and related problems:
A. Whenever there is gas flows through preheater, there should be air flowing through
preheater.
B. Frequency conversion slow speed threshold only can be used for emergency and
maintenance, when adopting frequency conversion slow speed threshold to drive air preheater,
rotor speed can slow down to 1/4r/m or even slower (sealing abrasion may occur when rotor
speed is lower than 1/8r/m).
C. Air preheater should be isolated before operation.
During starting up and operation, when temperature of gas inlet, gas outlet, air inlet and air
outlet keep at or lower then design temperature under BMCR working condition, and clearance of
preheater sealing and sealing surface are well regulated, it is not necessary to take special
measures to stop abrasion of sealing system.
1.5.0 Avoid secondary combustion accident at boiler tail
Rotary air preheater is equipped with reliable stop alarming device, perfect flushing system
and necessary alkali cleaning measures and alkali cleaning system that can be put into operation
at any time during boiler shutdown.
Fire fighting system connects with steam soot blowing system if air preheater; if it is
necessary in hot state, put steam in for fire fighting with isolating air. Fire fighting water spraying
pipe should be installed at air side and gas side for rotary air preheater, spraying area should
cover the whole heating surface.
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Operation manual has clearly regulated gas humidity limit value of economizer and air
preheater under different working conditions. When gas temperature exceeds regulated value, the
boiler should be stopped immediately. Fill gas duct fully with steam by using soot blowing steam
pipe or special fire fighting steam and put into fire fighting water for putting out fire.
Regulate working condition of boiler pulverizing system and burning system, avoid unburned
oil or coal powder accumulation at tail heating surface or on gas duct.
Inlet & outlet gas & air damper of rotary air preheater should be able to be driven by motor
and can be opened fully and closed strictly.
Recirculation should be set for flush water pump of rotary air preheater, a short time start test
must be done before every ignition to ensure flush pump and its system are in fine standby state
and with condition of putting into operation at any time.
If rotary air preheater is found stopped, it should be isolated immediately, start fire fighting
steam and turning gear. If damper isolation is not strict or rotor can not be turned, boiler should be
stopped immediately.
Soot blowing should be done continuously when boiler load is lower than 25% rated load,
once per 8 h soot blowing should be done if boiler load is higher than 25% rated load; when
differential pressure at gas side of rotary air preheater is increased or coal and oil are burning in
mixture with low load, soot blowing times should be increased.
If boiler burns with mixture of oil and coal under low load, check the heating surface of air
preheater according to specific condition during boiler shutdown period, especially check middle
layer and lower layer heat transferring elements, it should be cleaned with alkali if dirty is found.
For boiler that stopped for more than a week, rotary air preheater must be checked, it should
be cleaned and ventilation & drying should be done if oil dirty or ash block occurs.
1.5.1 Safety
materials should be comply with Safety Rules.
1.5.2 Health
1.5.2.1 Measures avoiding breathing gas and dust must be done when entering into gas duct.
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completed.
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Part Three Ash Handling System Equipment Maintenance Regulation
Chapter Slag Removing Equipments Maintenance Regulation
1. Applicable range: this regulation is applicable for slag removing equipments overhaul and
maintaining of Indonesia Paiton 1660MW coal fired thermal power plant.
2. Quoted standards:
1DL-T 748.72001 Guide of maintenance of boiler unit for thermal power station
Part Seven: Ash Handling and Slag Removing System Overhaul
2 Carbon Steel Castings for General Engineering Purposes GB11352-89
3 Design code for the steel structures GBJ17-88
4 Fixed steel oblique ladders GB4053.2-83
5 Fixed steel industrial platform GB4053.4-83
6 Insulation and painting design technical regulations of thermal power plant

equipments and pipelines DL/T5072-1997
7 Code for design of noise control in industrial enterprises GBJ78-85
8 General technical conditions for welding JB/IQ4000.3
9 Basic type and dimension of welding connector GB985-986-88
10 Carbon structural steel and low-alloy structure cold rolled sheet and strip
GB1153-89
11 Technical conditions of common carbon structure steel alloy steel plate
12Ordinary carbon structural steel and low-alloy steel cold-rolled sheet and strip
technical conditions GB699-88
13Technical specification of high manganese steel castings GB5680-85
14Technical Rules for the electric power construction and acceptance DL5007-92
3. Brief introduction
3.1 Boiler technical conditions
Boiler type: the boiler circulation controlling, four-corner tangential burning, once-middle
reheat, single furnace with balancing ventilation, solid residue discharge, whole steel structure
type steam drum boiler. Maximum consumption of design coal is 376.3t/h and maximum
consumption of checked coal is 390.0t/h; boiler lower header center nominal height is 8.00m,
boiler slag removal exit throat dimension is 26000mm1500mm, lower header water sealing plate
is 800mm250mm, lower header water sealing plate bottom nominal height is 6.76m, boiler slag
removing temperature is 800 and wet slag accumulation density is 1.4t/m 3.
Boiler working pressure:
Name Normal running value Alarming value Protection value
Furnace pressure +124Pa +498Pa +1370Pa
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-249Pa -747Pa -2500Pa
Cooling water of all equipments adopt closed circulating cooling water (dematerialized water),
its main index is as following:
SiO220g/l Conductance rate 0.2s/cm
Cooling water working temperature: 38 in maximum; cooling water working pressure:

0.4Mpa.
Make-up water of submerged scraper conveyer adopts industrial waste water after treatment in
centralized industrial wastewater treatment plant, the main indexes are as following:
PH value: 6~9 Suspended solids: 70mg/l
Salt content: 5000~6000mg/l Working pressure: 0.3~0.4MPa
Air supply pressure of unit and instrumental compressed air system is 0.450.8Mpa and
maximum temperature is 50.
3.2 System Brief Introduction
A set of submerged scraper conveyer is installed under each cold ash hopper, bottom slag
enters into cooling water of slot on submerged scraper conveyer for granulating and cooling, which
is then fished out slowly and continuously, dewatering is done in incline section to make water
content in discharged slag be 25, and then slag is discharged into slag silo for storage. Rated
output of submerged scraper conveyer is 200% of slag amount of design coal. Two slag silo are
set for each boiler for alternative application; boiler slag can be dewatered continuously in slag silo
and the effective capacity of slag silo can meet 24-hour-storage under BMCR. Wet slag after
dewatering is transported to ash ground for storage by automatic unloading automobile.
Overflowed water from submerged scraper conveyer can be used circularly after deposition and
cooling. Sullage subsided in deposition pool and cushion pool is discharged to submerged scraper
conveyer again through sewage water pump.
System sketch map:
4. Submerged Scraper Conveyer System
4.1 Slag Shaft
Slag shaft at upper section of submerged scraper conveyer is designed according to
materials offered by boiler manufacturer, slag shaft storage volume should be no less than
8-hour-dsicharging under BMCR, slag shaft supporting adopts separate supporting type. Its
supporting structure should be that: submerged scraper conveyer can be drawn out and there is
enough space for maintenance.
Slag shaft water sealing groove can absorb cooling water wall vertical and horizontal
expansion effectively, and cleaning & sewage discharging facility is set in water sealing groove.
Slag shaft resistant temperature should be no lower than 800 and slag shaft outside
temperature is lower than 50.
Slag shaft lining should be with anti-shock ability and its life is no less than 100,000 hours.
Slag shaft water sealing groove is arranged along circumference of slag shaft, continuously
supplied sealing water keeps water level in sealing water groove and sealing of slag sealing; high
temperature resistant slag baffle is set inside (inside boiler) for water sealing baffle of water
sealing groove.
Slag shaft water sealing groove and water sealing baffle are designed to be able to meet
requirements of maximum pressure and minimum pressure with sufficient surplus.
Footpath is set around slag shaft water sealing groove for patrol, upper berth ladder is
installed from zero meter to footpath and vertical ladder is not adopted.
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Technical data:
No. Parameter Unit Value
(1) Type self-supporting self-supporting type
(2) Pole quantity 8
3
(3) Effective cubage m 135
(4) Material Q235A
(5) Steel plate thickness mm 6
(6) Footpath width mm 800
(7) Sealing water amount t/h 6
(8) Sealing water pressure MPa 0.2
(9) Cooling water amount t/h 14
(10) Cooling water pressure MPa 0.2
(11) Water sealing height with lower header mm 520
(12) Water sealing height with submerged mm 450
scraper conveyer
(13) Slag shaft resistant temperature 800
(14) Slag shaft outside temperature 50
(15) Dimension (length width height) mm 23.9x9.6x6.76

(16) Equipment weight (with refractory t 55/140
material/without refractory
material)
4.2 Submerged Scraper Conveyer
Submerged scraper conveyer consists of upper transporting slot fully filled water and lower
chain returning groove. Hot slag goes through furnace laryngeal, drops into upper groove of
submerged scraper conveyer and then discharged into bottom slag silo in sequence.
Upper groove intension can bear weight of water & ash and distortion due to static stress.
When fully filled with slag of more than 1m, groove can start scraper and chain to remove
accumulated slag immediately. Besides, its intension can absorb wallop of bottom slag dropping
without distortion; and it can solve the problems of big clinker and cracking of big clinker.
Upper groove is seal welded structure; emergency slag (water) discharging outlet is set at
side face to ensure water in water groove can be discharged rapidly. Check hole (window) is set at
both two sides of lower groove for watching working state of chain exteriorly. Considering
granulating of clinker sufficiently, groove water depth should be no less than 2.2mm; an automatic
make-up water system is set on upper groove to ensure that water temperature is no higher than
60, Drainage water device is set at bottom of lower groove.
Measures for cleaning loop ring are equipped for submerged scraper conveyer.
Hackle overflow weir and parallel tilted plate clarifier with sufficient area are set for submerged
scraper conveyer overflow device to ensure suspend solid concentration of overflow water of
submerged scraper conveyer does not exceed 300ppm when carpolite coal does or does not
enters into submerged scraper conveyer.
Rainproof and antifreeze structure facilities are set for the groove in the open air of exaltation
section of submerged scraper conveyer.
Chain tensioning device is equipped at tail section of submerged scraper conveyer; it can be
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regulated when chain is elongated due to abrasion. Chain trail section tensioning device adopts
hydraulic self-tensioning mode and effective journey of hydraulic tensioning device is 600mm.
Submerged scraper conveyer adopts sealed hydraulic drive device, which is equipped with
low temperature (-20) starting and oil station of which is equipped with electric heater. Hydraulic
drive device includes one motor and the motor can rotate in reversal.
One speed regulable submerged scraper conveyer is adopted for each boiler; its rated output
(low speed) should be no less than 5t/h, its chain speed is 0.8 m/min and its maximum output is
higher than 30t/h.
Idler pulley id installed at bending section of submerged scraper conveyer. Anti-abrasion
bearing is installed for all idler pulley to reduce pull of chain. All the idler pulleys submerged in
water are installed on short shaft (single supporting), which is supported by bearing installed on
groove. Double layer sealing piece, gasket and inner lubricating oil pressure ensure that water will
not leak from bearing area. All drive bearing and return bearing are supported by exterior ball thrust
bearing.
Technical data:
No. Parameter Value Unit
(1) Name Submerged scraper
conveyer
(2) Model SSC
(3) Set quantity for each boiler 1 set
(4) Normal output (calculated with dry slag) 5 t/h (per set)
(5) Output when soot blower is running (calculated t/h (per set)
with dry slag)
(6) Maximum output (calculated with dry slag) 30 t/h (per set)
(7) Scraper speed under normal output 1.38 m/min
(8) Scraper speed when soot blower is running m/min
(9) Scraper speed under maximum output 3 m/min
(10) Scraper width 1560 mm
(11) Scraper height 220 mm
(12) Scraper space 1088 mm
(13) Connection mode of scraper and chain Furcation pin type
(14) Submerged scraper conveyer total length 45000 mm
(horizontal)
(15) Submerged scraper conveyer rise height 14000 mm
(16) Submerged scraper conveyer horizontal length at ~24000 mm
lifting section
(17) Obliquity of inclined rising section 34
(18) Water depth in groove on submerged scraper > 2000 mm
conveyer
(19) Upper groove effective cubage 120 m3
(20) Horizontal height 3500 mm
(21) Horizontal width 2000 mm
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(22) Running mode Continuous running
(23) Drive mode Hydraulic pressure
(24) Tensioning device YZJ-600
(25) Chain specification 34x126 mm
(26) Chain material 40C-G/S4
(27) Speed regulation type Hydraulic no stage
speed regulation
(28) Groove lining plate material at horizontal section Lining plate 20Mn
(29) Lining plate material of inclined rise section and Lining plate 20Mn/
lower groove Lining plate
anti-abrasion cast
stone
(30) Shell material Q235A
(31) Chain idler pulley cleaning water amount 2 m3/h
(32) Overflow water quality 300 mg/m3
(33) Material of inclined purifier
(34) Area of inclined purifier 100 m2
(35) Dimension 3500x59500 mm

(36) Equipment weight 156 t
4.3 Belt Conveyer
Boiler slag is heightened to a certain height through submerged scraper conveyer and then
drops on belt conveyer and is distributed to two slag silo. Belt conveyer mainly consists of:
Roller: Roller adopts welding structure with steel plate, and is designed and manufactured as
per heavy grade work. Roller selection is strict; calculated according to rubber belt rubber belt
conveyer; its permit torque can meet requirements under starting condition and all kinds of other
working conditions. All rollers are rubber type, the rubber thickness of drive roller is 12mm.
Supporting roller: Supporting roller selects parallel type. The diameter of upper and lower
roller is 89mm. Muilti-labyrinth sealing is equipped inside supporting roller to avoid dust, dirty and
water invasion. Upper supporting roller space is 1.2m and lower supporting roller space is 3m.
Cusion supporting roller is adopted at fixed material accepting point; within range of material
accepting point of guide groove, supporting roller space is 400mm, three (3) rubber rings cleaning
supporting roller group is adopted near head. Self-aligning supporting roller adopts taper supporting
roller, one group of upper self-aligning supporting roller installed for every four (4) groups and one
group of lower self-aligning supporting roller installed for every four (3) groups.
Guide groove: Dustproof curtain is set for front section of guide groove, its sealing fittings
should be convenient for replacement after abrasion.
Brackets: All brackets, drive frame, head frame and tail frame of conveyer are made from
reasonable material to ensure sufficient rigidity and intensity. Welding line should be fixed,
beautiful and even; equipment surface should be smooth and free from burr.
Cleaner: To avoid felt material during rubber belt running and to reduce belt abrasion, cleaner
is installed at head and rubber belt drive place. Cleaner adopts hard alloy rubber cleaner, cleaning
rubber plate should be abrasion resistant and free from crack to ensure safe and reliable
operation.
Tensioning device:
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Safety protection device: Safety protective guardrails are installed at operation channel side
of rubber belt conveyer, protective cover or guarding bar should be set for rotating and moving
parts.
Belt: rubber belt is adopted.
Pull wire switch is equipped for belt conveyer.
Technical data:
(1) Type TD2
(2) Set quantity equipped for each boiler 1 set
(3) Double-head roller center moment 11 m
(4) Belt width 800 mm
(5) Belt output 60 t/h
(6) Obliquity =0
(7) Belt type Rubber belt 800x4 (4.0+1.5)
(8) Belt speed 1 m/s
(9) Motor power 3.0 kW
4.4 Slag Silo
One group of two slag silo is equipped for each boiler and arranged in slag silo house; slag
silo diameter is 6m. Slag has steel bracket and its wall thickness is no less than 6mm.
This equipment consists of steel structure, its upper section is column sleeve and lower
section is 60 taper sleeve; pneumatic slag removing valve and electromagnetism vibrator are
installed at lower section of cone. The main body consists of steel frame, sealing upper cover and
protective enclosure are designed for upper column sleeve and slag inlet is set. Steel platform for
operation is designed for main body lower section for the convenience of operating pneumatic slag
discharging valve.
Main components: silo body (main body), upper enclosure, level detecting machine, vibrator,
steel bracket, pneumatic slag discharging valve, slag dropping operation layer platform, enclosure,
upper berth ladder and equipment control box etc.
Working principle: Cone lower section removes surplus moisture in slag-water mixture, which
accumulates to upper level of silo body; level detector sends alarm signal and mixture stops
entering into silo. When mixture in silo reaches to proper humidity, operate the bottom slag
discharging valve to remove wet slag in silo through equipment control box for transportation; after
all wet slag in silo is discharged, recover above operation. Two silo wall vibrators are equipped for
each slag silo with power of no lower than 750W.
Pneumatic slag discharging valve is set under slag silo with diameter of DN900, the valve
can be opened or closed freely and controlled as per any settings. It should be free from lekage
after it is closed.
Grid plate platform is set on top of slag silo. Upper berth ladder is set from ground operation
layer to top and vertical ladder should be adopted from silo top to head of submerged scraper
conveyer.
Head of submerged scraper conveyer and belt conveyer are set on top of slag silo,
motor-driven single beam hanging type crane is set on top of slag silo layer.
Technical data:
No Parameter Value Unit
208
No Parameter Value Unit
(1) Type Sleeve type steel silo (bottom is taper)
(2) Set quantity equipped for 2 set
each boiler
(3) Slag silo diameter 6 m
3
(4) Slag silo effective cubage 60 m /set
(5) Element quantity 4 pieces at cone partsilo
Ring type water analyzer 1 piecesilo
(6) Slag discharging dimension 900 mm

(7) Slag discharging type
(8) Vibration type and power ZF10 electromagnetic vibrator

(9) Dimension About 6000x11000 mm
(10) Equipment weight 8600 kg
5. Slag-water Circulating System Equipment Specification
5.1 Slag-water Circulating System Description
Slag removing and water reclaiming system mainly consists of slag-water circulating water
pump, two-stage deposition pool, cushion pool, sewage pump, plate heat exchanger and
automatic backwash device.
5.1.1 Slag removing circulating water system description
Overflow water of submerged scraper conveyer is discharged into first stage deposition pool
(V=324m3), enters into second stage deposition pool (V=264m3) and then flows to cushion pool
(V=108m3) after deposition in deposition pool. Water in cushion pool is supplying water of
slag-water circulating pump and is also used for cooling sealing of submerged scraper conveyer.
Plate type slag removing heat exchanger is set at outlet of slag water circulating pump to ensure
cooling water temperature of scraper and to fatherly cool reclaimed water. Cooling of slag
removing heat exchanger comes from closed industrial cooling water system; overflow water of
slag silo is discharged into blowdown pool and then flows through two sewage pumps to
submerged scraper conveyer or overflows to industrial waste water pool.
5.1.2 Ash handling water user
Water supplying system offers high pressure flushing water, middle pressure serving cooling
water, cooling water of rotating equipments and bearing gland sealing water for ash handling
system. Water supplying source and users:
The first line is supplied by closed industrial cooling water with main users as following:
Air compressor cooling water Ash silo gasification air fan cooling water
Slag removing heat exchanger cooling water Slag water circulating pump sealing water
The second line is supplied by middle pressure serving water offered by industrial waste
water plant with main users as following:
Submerged scraper conveyer cooling water Slag silo flushing water
Using water of wetting device for dry ash Using water of flushing water tank
5.1.3 Slag removing circulating water running description
One (1) slag removing circulating water pump pool is set for each boiler. Two slag water
circulating water pumps are set for ash handling circulating water pump pool, one is in operation
and one is in standby; two sewage pumps are set for each boiler with one in operation and one in
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standby; two backwash filters are set for each boiler with one in operation and one in standby.
5.1.4 Automatic backwash device working principle
Automatic backwash filter working principle: working liquid enters into inside of filter through
inlet end of filter, granules with particle bigger than dimension of filtering element mesh are cut off
and left inside screen, filtered liquid flows out from outlet of filter.
When granules cut off inside screen accumulates to a certain degree, which makes differential
pressure of inlet & outlet ends increase to set value of differential pressure controller; differential
pressure sensor drives program controller to work, opens blowdown solenoid valve and starts
automatic backwash turning arm for backwashing. At this time, filtered liquid returns to screen
through filtering liquid cavity, enters into turning arms aperture of backwash arm and bring
granules attached on screen. The granules are discharged out from filter through empty axes of
backwash arm and blowdown solenoid valve. Thus, differential pressure recovers and filter
recovers to normal working state.
5.2 Slag Water Circulating Pump Parameter
Flushing water Sewage water Remark
Slag water pump
pump pump
Manufacturer Shijiazhuang Shijiazhuang Shijiazhuang
Industrial pump Industrial pump Industrial pump
factory factory factory
Type 80ZJL-A36-330 80ZJ-I-A52 40ZJL-B25
Quantity (set) 2 2 2
Pump rotating
1250 1240 1440
speed r/min
Cooling water
amount and / / /
pressure
Gland sealing type Single end
Auxiliary impeller +
mechanical sealing /
stuffing material
with no water
Sealing water
amount and / 1.2m3/h/0.4MPa /
pressure
Pump efficiency 58% 53.5% 37%
Shaft power of
18.5 58 3.1
pump kW
Anti-abrasion part
GLH-1 GLH-1 GLH-1
material
Anti-abrasion part
8000 8000 8000
life (h)
Drive type DC ZV DC
Motor
Type Y225S-4 Y280S-4 Y132S-4
Power (kW) 37 75 5.5
Voltage (V) 380 380 380
3.5 Slag Removing Heat Exchanger
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1 Name Heat exchanger
2 Model BR0.8-0.8-100-N
3 Heat exchanging type Heat exchanging with
adverse current
4 Working pressure 0.6 MPa
5 Design pressure 0.8 MPa
6 Test pressure 1.0 MPa
7 Design temperature 100
8 Heat exchanging area 100

9 Heat exchanger plate material/thickness SUS316L/1.0mm
10 Heat transferring coefficient of heat 3000 W/.K
exchanger (design)
11 Heat transferring coefficient of heat 2800 W/.K
exchanger (running)
12 Logarithm temperature difference f heat 11.3
exchanger
13 Primary water inlet temperature 60
14 Primary water amount 120 m3/h

15 Primary water outlet temperature 40
16 Primary water suspend solid content 2000 mg/l

17 Primary water suspend solid maximum 2 mm
particle diameter
18 Primary water inlet pipe diameter DN175 mm
19 Primary water outlet pipe diameter DN175 mm
20 Primary water pressure drop 0.035 MPa
21 Primary water side dirt coefficient 0.000043 ./W
22 Secondary water inlet temperature 33
23 Secondary water amount 240 m3/h

24 Secondary water outlet temperature 43
25 Secondary water suspend solid content 100 mg/l
26 Secondary water pressure drop 0.045 MPa
27 Secondary water side dirt coefficient 0.000034 ./W
28 Secondary water inlet pipe diameter DN175 mm

29 Secondary water outlet pipe diameter DN175 mm
30 Sealing ring material
211
31 Sealing ring connection manner Connect by mucosity
32 Heat exchanger life 15 year
33 Dimension (length width height) 14567251880 mm
34 Equipment weight 2295 kg
3.6 Automatic Backwash Filter
There are four automatic backwash filters in total. Automatic backwash filter is used to filter
the overflowed water from submerged scraper conveyer. The characteristic of overflowed water is:
little slag particle, with grinding and pecking force, easy to deposited and form dirty. Above factors
are taken into consideration for selection and design of automatic backwash filter.
1 Name Automatic backwash filter
2 Model DWC-6D
3 Working flow 150 m3/min
4 Working pressure 0.8 MPa
5 Design pressure 1.0 MPa
6 Inlet water temperature 60
7 Inlet pipe diameter DN150 mm

8 Outlet pipe diameter DN150 mm
9 Backwash form Differential pressure
control negative
pressure suction type
10 Suspend solid content in inlet water 2000 mg/l
11 Suspend solid content at outlet Cut off 2mm granule
12 Main type of suspend solid Solid particle
13 Filter shell material Carbon steel
14 Screen type Cuniform net
15 Screen material 1Cr18Ni9Ti
16 Filtering precision 2.0 mm
17 Backwash motor power 0.18 kw
18 Backwash motor volatge 380 V
19 Backwash flow 5 m3/h
20 Backwash time 10 S
21 Backwash pipe diameter DN40 mm
22 Equipment dimension 2695 mm
23 Equipment weight 450 kg
4. Preparation before Overhaul
4.1 Training for the maintenance personnel before overhaul
4.1.1 Working personnel for maintenance must be experienced workers who meet basic
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requirements of three familiarities and three abilities. Three familiarities means: be familiar
with structure and performance of system and equipment, be familiar with assembling process,
process and quality standards, be familiar with safety construction regulations; three abilities
means: be able to grasp locksmith process be able to do one or two kinds of work related
to his own work, be able to read drawings and protract simple parts diagram.
4.1.2 Organize maintenance personnel to learn, discuss overhaul plan, items, and schedule,
measures, process and quality requirements before overhaul for the convenience of controlling
schedule reasonably.
4.1.3 Work principal should check equipment running condition (such as leakage points, vibration
and temperature of rotating bearing part) completely before maintenance and record it well.
4.1.4 Prepare general tools for maintenance (sledge, hammer, screwdriver, spanner, sleeve
spanner, hammer spanner, cold chisel, file, copper stick, crowbar, sand paper and mark pen);
lifting tools (jack, chain block, steel wire rope, flying rings and block rings); measures (tape, ruler,
corner ruler, calipers, feeler gauge, inner & outer micrometer and measuring block); electric tools
(angle grinder, hand driller, grinder, welding machine and cutting machine) and gas cutting tools
(oxygen, acetylene, cutting gun and baking torch).
4.1.5 Prepare necessary spare parts and common materials.
4.1.6 Arrange working site, check and install lighting facilitates.
4.1.7 Transact work permit ticket, arrange safety measures, danger factor controlling measures
and then start working.
4.1.8 Prepare common materials and spare parts
4.2 Equipment major overhaul, minor overhaul standard items
4.2.1 Preparation
4.2.2 Move the whole submerged scraper conveyer completely.
4.2.3 Repair, regulate and turn over scraping plate and round loop chain; build-up weld abraded
surface.
4.2.4 Repair tensioning device.
4.2.5 Repair upper idler pulley group and lower idler pulley group.
4.2.6 Check and replace transmission chain wheel group and chain gear.
4.2.7 Clean, check and replace bearing of rotating parts.
4.2.8 Check anti-abrasion lining plate, refractory; repair shell and structure of body, cold ash
hopper, sealing water groove; check and repair abrasion of chute abrasion.
4.2.9 Repair water pipeline system and valve.
5 Maintenance Process and Quality Requirements:
213
Maintenance
No. Main working process and contents Quality requirements Notices
item
1. To check, collect equipment defects and leaking Defects are completely collected and 1. Scraper must run for 1-2 days after
points and make operation records (e.g. vibration, sound equipment status is completely, rightly and boiler stops until there is no slag or
and temperature of all parts of motors and reducer) well truly recorded. coke discharging out to avoid big coke
of running equipments before maintenance. dropping after scraper stops which
increases workload or equipment,
2. To prepare tools and instruments, security apparatus Complete, qualified, safe and be with fine
personnel accident due to coke
and illumination devices. condition.
dropping.
3. To check the delivery of spare parts and main Materials certificates are complete and 2. Safety tests must be done for lifting,
maintenance materials. materials are accepted. electro motion tools before using in
4. To disclosure security and technical issues and to Personnel know the plan, item, schedule, maintenance to ensure that
train personnel in working team. measures and quality requirements of this maintenance tools and apparatus are
1 Preparation maintenance and have met the basic qualified, safe and healthy.
requirements of three familiarities and 3. Operation and maintenance
three abilities. personnel must execute Machinery
5. To transact working permit ticket and verify safety Working permit ticket should be written Working Permit Ticket Rules and
measures. according to criterion with clear and Supplementary Regulations of
specific working contents, the safety Machinery Working Permit Ticket Rules
measures are complete and right and strictly.
analysis of dangerous points is right and
perfect.
6. To execute safety measures arrangement. Work approver and work principal must
go to site together to carry out safety
measures one by one.
1. Temporary fixing of slag chute of scraper Fixed and reliable 1. Dismantle taper short joint flange, if
flange clearance if too big, it is
2. Dismantle the flange of taper nipple between slag Connection flange of taper nipple should
necessary to cut capitulum pipe plate of
Whole scraper barrel and tee damper, clean bedding material on flange not be damaged and there is no impurity
taper pipe.
2 moving out junction surface. such as welding knob on flange junction
test surface which should be smooth not 2. Valves in water system can not be
influencing moving out, and the clearance closed strictly, it should be grinded or
between flanges 20mm. replaced.
215
3. Close chain rushing water valve and cut off pipeline Chain rushing valve is closed strictly. 3. Detain work permit ticket in operation
behind the valve. duty room and start scraping slag for
2-3 hours to scrape residual slag.
4. Dismantle control cable tray of the scraper and Make sure that all the control cables are
smooth out all the cables of the scraper, check whether with 3-4m redundancy. 4. The device can only be moved out
there is any cable influencing moving out scraper, after chain returning bottom and tracks
regulate it properly if there is. are completely cleaned to avoid
accidents such as distortion or damage
All the tracks are smooth and their groove during moving.
5. Check and clean chain slot bottom, impurities in such cleaning depths are the same, chain slot
as accumulated slag, cement and carry-over in track top bottom reinforcing steel bar has no 5. Press control button slightly when
and side of moving out wheel. distortion and ground is smooth that not moving device out to check whether all
influencing whole moving out. wheels traveling directions are same or
not. It can be formally started after
6. Move out drive device reducer, transferring gear, Lubrication should be sufficient and confirming that there is no wrongness to
check and clean all the lubrication of bearings of moving proper. avoid damaging overflow groove due to
wheel and fill lubricate oil. wrong traveling direction.
7. Check connections and insulation of the moved out Insulation is fine, connections are fixed 6. Start and stop for moving out device
drive device motor and cut off moving bearing gear, run and turning directions right. must be operated by operators; before
the drive device with empty load to judge turning operation, special personnel must be
direction. sent to A, B drive mechanism,
8. Close water filling valve of scraper water sealing slot, Valves are flexible and strictly closed. submerged scraper conveyer head and
slot water supplementary valve and water all the traveling wheels for supervision.
supplementary master valve. 7. Special personnel must be sent to
Valves are flexible and strictly closed, supervise groove at overflow water side
9. Open slot blowdown valve to discharge water. accumulated water in slot can be and all idler wheels to avoid excessive
completely discharged. traveling and damaging overflow water
groove.
10. Finally, carefully check the scraper round, mark Scraper moves stably and smoothly,
location signs for scraper after making sure that there is moving and recovering are free and
no component or cable influencing whole moving out, scraper has no distortion, damage imprint
start moving device to move the scraper to maintenance etc.
position and cut off power supply of moving out device.
216
11. Recover the scraper after all the maintenance work is The location of recovering scraper should
finished and recover the working contents in item 4, 5, 6 not be with error more than 5mm, all the
and 7. connection parts are right and sealing are
strict.
1. Open blowdown valve to rush plaster and residual Clean the mud and slag 1. When loosen tensioning device by
slag on the body, chain and scraper plate. regulation, jacks under moving guide
frame of bearing seat at two sides
2. Regulate the loosened tensioning device Moving guide frame of bearing seat acts
should be lowered evenly.
freely and free from block or distortion,
regulate screw stem and nuts. 2. Two heads of every 7 loop chain
group is connected by two U type
3. Open maintenance manhole at tail section of scraper Maintenance manhole should be put in connection rings; during alternative
Repair and
proper position and well preserved, clean exchanging, 7 loop chains must take a
regulate
the accumulated slag at tail. U type connection ring for exchanging
scraper and
round ring 4. Enter into groove through the fourth check hole of tail Screw threads of U type connection ring at the same time.
3
chain, chain returning groove, dismantle 1 scraper plate and and tightening knurled nut should not be 3. If length difference of scraping plates
build-up draw out the 8m chain plate from tail overhaul door. damaged; scraping plate, chain and
is cleaned by regulation, alternative
welding for Dismantling sequence of scraping plate: Spray bolt relax accessories must be cleaned.
exchanging is not necessary for the rest
abrasion. agent on U type connection screw, draw out knurl nut scraping plate chain, just turn over it
stop pin, screw off knurl nut, prize out U type connection
directly.
ring from screw holes and take off scraping plate, demount
connection ring block, take out U type connection ring from 4. If part abrasion of chain is serious
chain ring and clean impurities on parts. Principally, air and needed to be exchanged, the
cutting should not be adopted to demount chain, unless U corresponding two chains must be
type connection ring is in serious distortion and bolts screw exchanged symmetrically to avoid
threads are seriously damaged. resulting length error of the two chains
217
5. Check the abrasion of 8m scraping plate chain, mainly Scraping plate should be complete and due to inconsistent abrasion.
check: whether scraping plate is in distortion or not; free from distortion, welding crater of all
5. If submerged scraper conveyer is
whether end part and abdomen welding crater have parts should be free from welding seam or
needed to be started during
welding seam, crack or not; whether round chain welding crack, wing edge abrasion 4mm; round maintenance, all maintenance
crater is free from seam, crack or not; whether U type
chain loop welding crater should be free personnel must leave away before
connection ring is in distortion or not. Record diameter of
from seam and crack; U type connection starting; submerged scraper conveyer
contacting points of U type ring, round chain ring after
ring should be free from distortion and can only be started after confirming that
abrasion.
round ring diameter 20mm. Knurled nut there is no tool left in submerged
scraper conveyer.
screw threads should be complete and
free from crack or dilapidation. 6. Build-up welding must be done
alternatively for two abraded pits on one
Check and find out the scraping plate,
scraping plate to avoid heat distortion
round chain loop, U type connection ring,
during welding for pits on main abraded
knurled nut that exceed standard and they
surface of scraping plate.
should be replaced one by one (if the
welding crater at end or abdomen of 7. After reinstalling and replacing chain
scraping plate have welding seam or plate, check and confirm that nuts are
crack, repairing welding should be done screwed down; correct it timely if any
after welding seam is grinded, repairing problem exists.
welding line should be 2 times of crack
length).
After repairing chain, regulate tensioning
6. Strain the chains at two sides at the same time and device to make tensioning stress at two
find out chain groups with length error, regulate it. If sides of chain proper and even. Total
there is no obvious error, exchange them every two length error of chains at two side should be
groups.
10mm.
7. After exchanging chains, draw out 8m scraping chain After turning over, end plate ears at two
and turn it over 180 to make the mainly abraded surface ends of scraping plate should face to
of scraping plate face up, and then send it to lower machine head with same direction.
groove of submerged scraper conveyer, connect it with
U type ring at breaking point. Do not install scraping
plate now.
218
8. Recover tensioning device, regulate it to make Horizontal deflection of tension wheel
tensioning stress of chain at two sides even and proper,
5mm
detect whether total length error of chains at two sides
are cleaned or not. Detect by measuring level degree of
tensioning axle to watch scraping plate deflection.
9. Start submerged scraper conveyer slowly and pull 8m
scraping plate chain back to upper groove, repeat item
4, 5, 6, 7, 8 and 9 until all 120 groups of chains are
repaired.
10. Build-up welding of pit on mainly abraded surface of Build-up welding surface should be even,
scraping plate. Build-up welding should be done in groove plump, smooth and free from crack,
of submerged scraper conveyer; build-up welding should delamination and slag inclusion; the
be done alternatively for two pits on abraded surface of one surface should be grinded with angle
scraping plate to avoid hot distortion to scraping plate. After grinding machine after build-up welding; its
build-up welding is done in upper groove, start submerged smoothness and
scraper conveyer to turn it back to chain groove and then
continue build-up welding for other scraping plates until all
of the plates are finished.
11. Replace whole chain of scraping plate. Before All material certificates are complete,
replacement, connect U type connection ring with 7 loop qualified and accepted, pitch error of every
chain, put them on smooth groups with 1 piece of 10m 10m should not 2mm and total length
for detecting its total length and pitch error. If the total
length and pitch are free from error, then install scraping should not 5mm.
plates on (reinstalling sequence is opposite to
dismantling sequence in item 4), and then repeat item 4,
5, 6, 7, 8 and 9 with changing maintenance to
replacement.
219
1. Check tensioning device supporting frame and Supporting steel structure should be not 1. Cloth for cleaning machine should be
moving guide frame of bearing seat. complete. Moving guide frame of bearing used to wipe dirty, accumulated ash
seat can move freely and is free from and impurities on bearing seat before
Mainly check: whether supporting frame steel structure
block, lubrication of regulation screw stem cleaning bearing to avoid entering of
has obvious distortion or not, welding crater has welding
and nut are fine and free from dilapidation; impurities into bearing and resulting in
seam, crack or not; whether anchor bolts of bearing seat,
all bolts are tightened. artificial damage to bearing.
tightening bolts of bearing cover and limit bolts of
bearing seat have looseness or not; whether regulation 2. Regulation wheel group is needed to
Tensioning screw stem has bending, breaking and rust or not; be dismantled only when tensioning
4 device whether upper lock pin and lower positioning pin have assembly needs replacing bearing,
overhaul looseness or not. wear resistant bushing or idler pulley
2. Clean and check bearing, replace lubrication grease. Item 7 abrasion exceed standard and need
See as in Item seven. build-up welding.
3. Clean accumulated slag, rust on tension idler pulley Wear resistant sleeve is free from 3. The purpose for dismantling should
and wear resistant sleeve; measure and check abrasion. dilapidation or distortion, idler wheel is be clear and dismasting range should
evenly abraded and outer diameter be controlled in minimum range as
much as possible. If any difficulty
abrasion 10m. occurs during dismantling, best scheme
220
4. Dismantle and repair regulation wheel group. Dismantling of regulation wheel group should be analyzed and confirmed, and
Sequence for dismantling: loosen tensioning device, should be done supervision of then dismantle it, loss should be
experienced worker; artificial damnification controlled within minimum range as
open manhole at tail of submerged scraper conveyer,
due to overhaul process is prohibited. much as possible.
break off chain of the scraper (see as in item3.4); Dismantled parts should be put designated
4. Marks should be made for all parts to
dismantle limit connection plate on top of tensioning location for preservation after cleaning to
be dismantled before dismantling idler
frame, set the lifting point above regulation axle, hang on avoid losing or knocking.
wheel group, especially the distance
chain block and fasten steel wire rope in groove of idler
between two wheels.
pulley; dismantle bearing end cover, demount
5. During lifting in maintenance, related
tightening double-end bolts of bearing seat upper cover,
regulations in section three Steel wire
take off bearing positioning pin, knock junction part of
rope, fiber rope, suspending hook,
bearing seat upper cover and bearing seat with copper
pulley, jack and chain crane of chapter
stick to separate them, insert crowbar into lifting ears of
fourteen Lifting and conveying (thermal
bearing seat upper cover and lift it down; lift and mechanical part) of Working Safety
regulation axle stably to make it separate from bearing Regulation of Electric Power Industry
pedestal, introduce it with rope and put it on laid crosstie; must be executed; the work should be
dismantle lock nut, stop gasket, bearing, idler wheel done under supervision of special lifting
worker, all the process of lifting and
fixing bolts and idler pulley in sequence; check and lowering should be done carefully to
record damage and abrasion of all parts, repair, weld, avoid accident due to collision of
process or replace them accordingly. Dismantling and components.
installing bearing see as in item 7.
221
1. Check sealing of upper idler pulley hub cover, the Strict with no leakage. 1. Sealing gasket of idler pulley hub
sealing gaskets should be replaced if there is leakage. cover should be replaced, and the
loosen tensioning device and pull out chain from idler gasket must be made by 3mm black
pulley groove; after making dismantling marks, rubber, tightening stress of bolts must
be even to avoid error between two idler
dismantle tightening bolts of the hub cover, suspend the
pulley chain grooves that may influence
hole on hub cover plate to draw out the idler pulley
running of scraping plate.
group; clean hub cover, sealing surface and screw
2. The purpose for dismantling should
holes, measure dimension of original sealing gasket and
be clear and dismantling range should
machine body sealing surface, make new gasket with
be controlled in minimum range as
3mm black rubber; spread sealing glue on the two much as possible. If any difficulty
Overhaul of
upper idler sides of new gaskets, aim at screw hole and adhibit occurs during dismantling, best scheme
5 pulley and them on hub cover sealing surface; lift idler pulley should be analyzed and confirmed, and
lower idler then dismantle it, loss should be
and push it into machine by aiming at dismantling marks controlled within minimum range as
pulley and screw holes, tighten the connection bolts evenly and much as possible.
symmetrically; encase chain into idler pulley chain
3. Marks should be made for all parts to
groove. be dismantled before dismantling idler
2. Clean and check bearing, replace lubricating grease; wheel group, especially the distance
anchor bolts of bearing seat, tightening bolts of bearing between two wheels.
See as in item 7.
cover and bearing seat limit bolts are free from 4. During lifting in maintenance, related
looseness. See as in item 7. regulations in section three Steel wire
3. Clean accumulated slag and rust on upper and lower Axle is free from damnification or rope, fiber rope, suspending hook,
idler pulley and axle surface, check and measure distortion, idler wheel abrasion is even and pulley, jack and chain crane of chapter
fourteen Lifting and conveying (thermal
abrasion. outer diameter abrasion 10mm.
and mechanical part) of Working Safety
222
4. Dismantle and repair idler pulley group. Dismantling Regulation of Electric Power Industry
and repairing of upper idler pulley refers to item 5.1, must be executed; the work should be
idler pulley dismantling and bearing demounting is done under supervision of special lifting
added after item . Lower idler pulley dismantling and worker, all the process of lifting and
lowering should be done carefully to
repairing sequence is: make dismantling marks and avoid accident due to collision of
measure the distance between two idler shell chain components.
grooves; dismantle fixing bolts of hub cover at two Dismantling of regulation wheel group
sides, open one bearing end cover, demount double-end should be done supervision of
bolts on bearing seat, take off bearing seat positioning experienced worker, artificial damnification
pin, take off bearing seat upper cover, dismantle bearing due to overhaul process is prohibited.
Dismantled parts should be put designated
lock nut, stop gasket and draw out bearing; pull
location for preservation after cleaning to
scraping plate chain out from idler pulley and draw out avoid losing or knocking.
axle completely from the other side; dismantle idler
wheels at two sides and bearing subassemblies at the
other side out of the body; check and record damage
and abrasion of all parts, and repair, weld, process or
replace them accordingly.
5. Marks made during dismantling should be prevailed Reinstallation positions of all parts are
for reinstalling of idler wheel group, and reinstalling right and free from wrongness and missing
sequence is opposite to dismantling. The distance and connections are reliable. Windage
between two wheels and level degree of main shaft between centerline of two idler chain
should be measured repeatedly after reinstalling, turn groove and vertical chain loop at two sides
the idler wheel manually to confirm that turning gear is
should 1mm, misalignment of main shaft
agile and turns freely and free from abnormity and noise.
Installation process of bearing subassemblies see as in should 2/1000; Turning gear turns freely
Item 7. and free from abnormity or noise.
223
1. Check bracket of bearing seat of main drive axle. Supporting steel structure should be not
Mainly check: whether supporting steel structure has complete. Moving guide frame of bearing 1. The purpose for dismantling should
obvious distortion or not; whether welding crater at all seat can move freely and is free from be clear and dismantling range should
parts have welding seam, crack or not; bearing seat block, lubrication of regulation screw stem be controlled in minimum range as
anchor bolt, bearing cover tightening bolt and bearing and nut are fine and free from dilapidation; much as possible. Dismantling for
seat limit bolt have looseness or not. all bolts are tightened. bearing system is sufficient to check
and clean, dismantle it as less as
2. Clean and check bearing, replace lubrication grease. Item 7 possible.
Check and
3. Clean accumulated slag, rust and oil dirty on surfaces 2. Marks should be made for all parts to
repair drive
of big & small gear, chain wheel, wear resistant bushing. be dismantled before dismantling idler
6 chain wheel
Check and measure abrasion. Mainly check: whether Wear resistant bushing is free from wheel group, especially the distance
group and
wear resistant has dilapidation and distortion or not; dilapidation or distortion, chain teeth between two wheels.
chain teeth
whether big & small gear teeth have dilapidation, crack abrasion height is smaller than 1/5 of 3. Chain teeth of two chain wheels
and breaking or not; whether joggling is fine or not; chain original height, gear teeth abrasion height should be dismantled symmetrically.
teeth of main chain wheel is split type, check whether is smaller than 1/3 of original height. Chain After replacing and installing one pair,
chain teeth and its connection bolts are loosened or not; teeth and wheel teeth are free from and then dismantle and replace the
whether joggling of chain teeth and scraping plate chain dilapidation, crack or breaking. Chain teeth next pair to avoid axes deflection of
is good or not; whether chain teeth is free from and its connection bolts are tightened. symmetric chain teeth that influences
dilapidation, crack and breaking or not. Repair, weld, joggling between chain and chain teeth.
process or replace them according to abrasion condition.
224
4. Replace chain teeth of main drive chain wheel, chain Chain teeth and its connection bolts are
teeth replacement sequence is: build up scaffold in tight and free from looseness or shaking;
joggling between new chain teeth and
slag chute sleeve of submerged scraper conveyer as
scraping plate chain are fine and free from
maintenance platform; demount fixing bolts of chain blocking.
teeth and clean impurities in bolts holes and chain wheel
hub groove; after embedding new chain teeth, insert
a piece of fixing bolts for orientation, orientate another
screw hole of new chain teeth according to screw hole
on hub, hinged manually at site; insert the other
fixing bolt, the two bolts should be tightened alternatively
and evenly; dismantle and replace other chain teeth
alternatively; start submerged scraper conveyer
slowly and watch joggling of chain and new chain teeth,
if joggling problem exists, electric grinding head should
be used to repair until joggling gets qualified.
225
5. Dismantle and repair drive wheel assembly. Dismantling of regulation wheel group
Dismantling sequence is: loosen tensioning device, should be done due supervision of
experienced worker, artificial damnification
break scraping plate chain at climbing section of
due to overhaul process is prohibited.
submerged scraper conveyer head (see as in item 3, 4),
Dismantled parts should be put designated
and fix scraping plate chains on upper and lower
location for preservation after cleaning to
grooves; dismantle moving flashboard at groove avoid losing or knocking.
head of submerged scraper conveyer, demount gear
wheel cover, set lifting points above axle and hang chain
block well, tie down chain wheel with steel wire rope;
dismantle bearing end cover, dismantle tightening
double-head bolts of upper cover of split type bearing
seat, take off orientation pin of bearing seat, knock
junction part of bearing seat upper cover and bearing
seat with copper stick to separate them, insert crowbar
into upper cover lift ears of bearing seat and lift it down;
lift axle stably to make it separate from bearing
pedestal, introduce and pull it out from groove
horizontally, lay down it on ground in inversion on
prearranged crosstie; dismantle end cover damper,
security pin, big gear wheel, coupling, bearing, lock nut
of chain wheel hub, stop ring and chain wheel;
check and record damage and abrasion of all parts, and
repair, weld, process or replace them accordingly.
6. Marks made during dismantling should be prevailed Reinstalling positions of all parts should be
for reinstalling of chain wheel group and reinstalling right and free from wrong installation,
sequence is just opposite to dismantling sequence. The connection are reliable and fit well. Error
distance between two wheels and level degree of main between groove of two idler wheel chain
shaft should be measured repeatedly after reinstalling, and vertical chain loop at two sides of
turn the idler wheel manually to confirm that turning gear scraping plate center distance 1mm.
is agile and turns freely and free from abnormity and Level degree of main shaft 2/1000,
noise. Installation process of bearing subassemblies see turning gear turns freely and is free from
as in Item 7. abnormity and noise.
226
1. Bearing group cleaning. open bearing box and Inner and outer surfaces of bearing group
and inside of rolling part should be clean
then record residual amount and color of lubricant, take
and free from impurities.
al little lubricant with fingers and rub it to feel whether 1. Dirty, dust and impurities on bearing
there is hard impurities and contamination or not; if there seat box and surfaces of bodies around
is, it shows that bearing is damaged; moisten high should be cleaned completely, then
quality brush with detergent (generally benzine or bearing box cover can be opened for
kerosene), clean the lubrication grease and adherence check.
on bearing box and inside bearing, then continues with 2. Sealing gasket must not be damaged
fine cleaning; fine cleaning is to immerse bearing in during dismantling bearing end cover, it
cleaning oil, revolve it when clean it; it is not necessary must be replaced if it is damaged; the
to demount bearing from main shaft for cleaning unless thickness of new gasket must be the
bearing is going to be replaced. same with the old ones.
Bearing
7 3. Fiber products such as cotton yarn
overhaul 1. Bearing outer ring, inner ring, rolling part
and retaining frame should be free from and clout should not be used for
following defects: obvious peeling on cleaning bearing to avoid broken fiber
2. Check bearing body. After cleaning bearing, mainly running surface; bearing color changes; involving into bearing. It is not
necessary to clean bearings with
Being cleaning and check
check: whether the four main subassemblies of parts have indentation and crack; retaining
sealing cover and dustproof cover.
frame rivet is tight and free from breaking
bearing outer ring, inner ring, roller and retaining frame
or falling apart; all rolling track and rolling 4. Bearing must not be enclosure in
have peeling, burn, crack, dilapidation, contusion, rust
surface should be smooth and free from polluted or wet environment during
and corrosion or not; measure radial oil clearance of contusion; there is rust or corrosion on checking bearing, oil paper plastic piece
bearing with feeler gauge to check whether abrasion parts surface. or similar material should be used for
exceeds standard or not. covering when work intermits.
2. Bearing radial windage is smaller than
3/1000 of bearing inner diameter, ball
bearing diameter windage 0.02mm.
227
3. Check bearing box. Mainly check: after cleaning Tightening bolts, pressing cover, vernier
and dustproof plug of bearing seat are
bearing box, check whether shell is complete or not and
complete; oil sealing is complete and free
whether it is free from damage and crack or not, whether
from distortion, crack, dilapidation or burr.
oil indicator is fine or not and whether indication is clear
Windage between radial plane and axial
or not; whether junction surfaces of bearing upper
level of bearing seat 0.04mm/m.
box and lower box is smooth or not; whether bearing
seat end cover, sealing pressing cover surfaces are
smooth or not; check whether sealing is fine or not,
which can judged from lubrication grease quality by
checking water content and content of ash and slag in it;
check whether anchor bolts and limit bolts are
tightened or not.
It is proper to fill 1/2-1/3 of space inside
bearing with lubrication grease, it should
4. After bearing cleaning is qualified, lubrication grease
be reduced to 1/3 when bearing is in high
or lubricating oil must be added timely to avoid rust
running speed; filling amount of lubricating
(lubrication grease should also be plastered on bearing
oil is to position of vernier, generally it
seat upper cover to avoid rust).
should inundate 2/3 of gear teeth or oil
splash ring.
228
1. If the dismantled bearing is going to be used It should be careful to dismantle bearings 1. Make sure that force impact
continuously, special dismantling tools should be to be used continuously; bearing should be position is right. Force should be
selected; if the bearing has already been damaged, damaged due to dismantling; shaft, effected on inner ring for bearing fitting
destructive dismantling can be adopted, but shaft, bearing box or other subassemblies with shaft and it should be effected
bearing box and other subassemblies should not be should not be damaged when dismantling outer ring for bearing fitting with bearing
damaged. bearing that is confirmed to be damaged. box shell to avoid distortion or pressing
wound to rolling part or rolling track.
2. Main dismantling methods: copper stick hammering
method, tool of this method is simple, but force impact of 2. Force should be affected
roiling bear is not even and slipping of copper stick may symmetrically; only hitting one side is
hurt retaining frame easily, copper scrap drops into not allowed, which may make bearing
bearing easily (not applicable to bearing to be used incline and gnaw at bearing.
continuously); fire welding for heating can adopted for
3. Clean shaft and bearing before
damaged bearing, and air cutting can be adopted for the
installing and dismantling bearing; no
bearing locked with shaft to cut it; bushing
Bearing dismantling
rust or burr is allowed.

hammering method, this method is more ascendant
than the former, knocking force can be evenly distributed
on the whole surface of rolling bearing end, inner
diameter of bushing should be al little bigger than
bearing diameter and its outer diameter should be
slightly smaller than bearing inner ring rolling track;
heating up method, heat up bearing before dismantling
to make bearing inner diameter expands and reduce
resistance during dismantling, hot oil pouring can be
used during dismantling, but the shaft nearby should be
covered to avoid heating (oil disc should be arranged
under it to avoid expansion of pollution area), fire
welding for heating can adopted for damaged bearing,
and air cutting can be adopted for the bearing locked
with shaft to cut it; dismantle it with gear puller, main
screw stem and axes line should be consistent and free
from deflection.
229
1. Clean bearing and related parts 1. Bearing rolling sound is mellow and free
from noise.
It is not necessary to clean for the bearings
lubricated with lubricant, with oil sealing or dustproof 2. Bearing vibration:
covers at two sides.
rotating speed 1000r/min 0.07mm,
1000r/min rotating speed 2000r/min
0.06mm;
Bearing Installation

0.04mm;
3. Bearing temperature:
Grease lubrication80
2. Check dimension and finish machining of related
parts. Lubricating oil 70
4. Bearing lubrication: lubricating oil and
grease are rightly selected, lubricating oil
is limpid and lubricating grease is clean;
lubricating oil and grease should be added
properly.
230
3. Installation methods
Bearing installation should be done according to bearing
structure, dimension and cooperation characteristics of
parts; press should be added on sleeve end surface and
press transmission through rolling device is not allowed.
Following methods for bearing installation are generally
adopted:
a. Press fit
Bearing inner ring and shaft is tight fit while outer ring
and bearing seat hole is lax fit. Press bearing on shaft by
press and then encase shaft into bearing seat hole
together with bearing, a assembling bushing (copper or
soft steel) should be filled on bearing inner ring end
surface during installation by press; assembling bushing
inner diameter should be slightly bigger than shaft neck
and its outer diameter should be slightly smaller than
bearing inner ring to avoid pressing on retaining frame.
When bearing outer ring fits bearing seat hole tightly and
inner ring fits shaft laxly, bearing can be pressed into
bearing seat hole; under this condition, assembling
bushing outer diameter should be slightly smaller than
diameter of bearing seat hole. If bearing ferrule fits shaft
and seat hole tightly, inner ring and outer ring should be
pressed into shaft and seat hole at the same time, the
frame of assembling bushing should be able to tight end
surfaces of bearing inner ring and outer ring at the same
time.
b. Heat fit
It is a method to transfer tight fit to lax fit by using hot
expansion though heating up bearing or bearing seat,
and it is a commonly used and labor saving method. This
method is applicable for bearing with great abundance.
Put bearing or ferrule of separable bearing into oil tank to
heat it up to 80-100 before installation, and then
installed it onto shaft after taking out from oil as soon as
possible to avoid untight cling of inner ring end face and
bearing shoulder due to cooling down. Axial tightness
can be done after it is cooled down. Heating up bearing
seat method is adopted to avoid contusion of fit surface
when bearing outer ring fits bearing seat made from light
metal tightly. A grid should be set a certain distance from
tank bottom when heating up bearing, or suspend
bearing with hook. Bearing can not be put on tank
bottom to avoid impurities entering into bearing or
231
uneven heating. There should be thermometer in oil tank
and oil temperature in oil tank can not exceed 100 to
avoid fire back effect that may cause decreasing of
rigidity of ferrule.
c. Tapered bearing installation
4. Check after installation. After installation, lubrication
grease or lubricating oil must be plastered timely to
avoid rust (Grease lubrication bearing seat upper cover
also should be plastered with a layer of grease evenly to
avoid rust). Mainly check: bearing rolling sound,
vibration, temperature and lubrication.
1. Check abrasion of wear resistant cast stone plate of It should be free from dropping, loosening, 1. Check and work in cold ash hopper
chain returning groove. and crack, breaking or chapping. only can be done after confirming that
there is no hanging coke or
The abrasion should not exceed 1/2, it accumulated slag; regulations in
2. Check abrasion of wear resistant steel plate track in
should be mended or replaced if its section three Work in Vessels of
box.
abrasion exceeds standard. chapter eight Pipeline and Vessel
Overhaul (thermal and mechanical
Limit blocking pad and supporting steel
Repair shells 3. Check abrasion of limit blocking pad and supporting part) of Working Safety Regulation of
pipes should be complete and free from
of wear steel pipes in body, reinforce supporting steel pipes by Electric Power Industry must be
welding crack or distortion; it should be
resistant lining welding. executed.
replaced if abrasion is serious.
plate, 2. Check and find out defects and
refractory, problems, repair work can only be done
scraper body, after analyzing reasons and making
8 water sealing sure treatment scheme.
groove and
steel 3. Electric Welding and Fire Welding of
structure; chapter twelve (thermal and mechanical
check and part) of Working Safety Regulation of
repair slag Refractory layer should be complete and Electric Power Industry must be
chute. 4. Check abrasion of refractory in cold ash hopper. free from distortion, dilapidation or crack executed during welding in
etc. maintenance period.
4. Work at High Altitude of chapter
thirteen (thermal and mechanical part)
of Working Safety Regulation of Electric
Power Industry must be executed
during working at high altitude in
maintenance period.
232
1. Work at High Altitude of chapter
1. Check leakage of make-up water, water sealing All pipelines should be smooth and free thirteen (thermal and mechanical part)
feeding water, overflow, blowdown and water from leakage; all supporting frames are of Working Safety Regulation of Electric
discharging system; check fastness of supporting frame. fixed according to regulations. Power Industry must be executed
Water pipeline
during working at high altitude in
system and
9 2. Repair valve. Check gland packing in stuffing room, if maintenance period.
valve
the gland packing has no compression abundance any
maintenance
more, it should be replaced. Check bending degree of Switch should be agile, strict and free from
valve stem, check whether screw threads has breaking, leakage.
biting, corrosion or not; check whether sealing surface is
free from corrosion and scar or not.
Cycloid star 1. Cut off and dismantle motor power supply of speed Transmission gear wheel cover should be 1. Check and dismantling speed
wheel speed reducer, clean its surface and remove dust, oil dirty and complete and firm. reducer should be done on
10
reducer impurities, dismantle protection cover of gear wheel maintenance platform; dust, oil dirty and
overhaul transmission. impurities on body surface and around
233
2. Dismantle speed reducer, it should be dismantled 1. Pin shaft and pin sleeve are free from platform should be completely cleaned;
from input end to output end gradually. distortion; abrasion 0.10mm. lay black rubber on platform and clean
cleaning oil disc and vessels.
Sequence of dismantling: Dismantle motor of speed 2. Cycloid gear is free from crack and
abrasion 0.15mm. 2. The purpose for dismantling should
reducer, because motor bearing of submerged scraper
be clear and dismasting range should
conveyer is a bearing with dedust cover at two sides, its 3. Pin shaft and pin sleeve are free from
be controlled in minimum range as
lubricating grease inside life is generally longer than distortion or bending; abrasion0.15mm. much as possible. Dismantling for
bearing life, if motor bearing vibration and temperature
4. Oil level indicator is free from bearing system is sufficient to check
are normal and there is oil pollution at motor side before
dilapidation and oil level display is clear, oil and clean, dismantle it as less as
submerged scraper conveyer stops, it is not necessary
level indication is right. possible.
to dismantle the motor; open oil discharging thread 5. Speed reducer runs stably and free from
3. Measures for preventing impurities or
block at bottom of speed reducer to discharge lubricating noise, all parts are free from oil leakage.
dust entering into body must be done
oil; dismantle connection bolts to separate needle when overhaul work stops, clean the oil
teeth shell and the body; dismantle flexible closing dirty in time. The dismantled parts must
be plastered with machinery oil or
ring of bearing, shaft end bearing and cycloid gear and
lubricating oil for rustproofing, they
record corresponding positions of gear surface mark and
should be preserved well and no
number relative to surface mark and numbers of the damnification due to collision is allowed
other cycloid gear; take out clearance ring; (especially that bearings to be used
dismantle eccentric sleeve and roller bearing; again should not be put together with
other parts, they should be packed with
dismantle another cycloid gear; take out needle oil paper and put separately).
teeth, needle teeth sleeve; demount end cover, Assembling must be done according to
dismantling marks. Incomplete, wrong
flexible closing ring of bearing, input shaft and sealing oil installation or leaving tools in speed
cover, knock out shaft end surface with mat of hard reducer is prohibited.
rubber, take output shaft out; assembling sequence
4. Directe hit by hammer on output
is opposite to dismantling sequence. bearing end, coupling, gear wheel and
3. Cleaning, check and dismantling of bearing see as in See as in Item seven. chain of speed reducer during
Item seven. installation is not allowed, screw in bolts
4. Clean inside of speed reducer box, wipe with white Shell is free from crack or other defects, by using extended end screw hole and
cloth and adhibit impurities with paste, box inside should shell inside is clean and free from press it by pressing plate. Hitting on
keep clean before assembling. impurities, box is free from oil leakage. inner parts by hammer is not allowed.
234
5. Replace oil sealing. Oil sealing should be complete and free 5. Do not damage sealing gaskets and
from oil leakage. sealing end surfaces as much as
possible during dismantling, it must be
6. Check foundation and anchor bolts. Foundation is fixed, welding lines at all
replaced if any sealing gasket is
supporting parts are from crack, bolts are
damaged, the thickness of new gasket
tightened and nuts are complete.
should be the same with old one,
7. Fill lubricating oil. Brand of lubricating oil is Omala 150, fill oil sealing glue should be plastered on
to vernier position, space ring must be plane before installation.
immersed.
8. Connect and install motor, turn air wheel of motor and Temperature and vibration are normal and
then hae trial run with empty load for the speed reducer. there is no noise.
Connections for all equipments and parts 1. Submerged scraper conveyer should
1. Check it completely before trial run, especially gear should be right and confirm, all lubrication run at least 2 hours for trial with empty
wheel drive mechanism, tensioning device, drive device points are with sufficient and proper load before running with load. During
and connection parts should be firm; lubricating oil is lubricating oil, all connections of electric trial run, check joggling of chain and
properly filled for all lubrication points; connections and elements and motor are right and scraper and chain wheel, clearance
insulation of electric elements and motors are fine. insulation are fine; tensioning stress of between chain scraper and all idler
chain is proper. pulleys; scraper chain should run stably
and all parts should be free from oil
2. After all maintenance works for submerged scraper It travels stably and orientates rightly.
leakage and water leakage.
11 Trial run conveyer are completed, maintenance personnel Submerged scraper conveyer box is free
evacuate from scraper; clean site, check and count from distortion. 2. Scraper chain should start with
tools; make sure there no components or cables around lowest speed and be regulated
the scraper affecting whole scraper recover; start moving according to principle of Raising speed
device to move scraper to running position. Specific gradually. In order to reduce abrasion,
items, notes and operation see as in Item Two of this its running speed should be regulated
chapter. to lowest speed that is proper to slag
discharging amount. When restart the
3. Fill water to submerged scraper conveyer groove and scraper after stop during operation, it
Be strict and free from leakage.
water sealing groove. also should execute low speed start
235
principle and it s speed should be
Run for 2h with empty load under three
4. After moving to running position, start main drive and raised gradually.
speeds, the submerged scraper conveyer
run with empty load with three scraper running speeds of
runs stably; scraper, loop chain and 3. Notes for resetting submerged
slow, middle and fast. Check that joggling of scraper,
dragging wheel should be fine and free scraper conveyer see as in Item Two
loop chain and dragging wheel should be fine and free
from chain block, chain climbing or of this chapter.
from chain block, chain climbing or blocking.
blocking.
1. Bearing rolling sound should be mellow

and free from noise.
2.Bearing vibration: rotating speed
1000r/min 0.07mm 1000r/min

rotating speed 2000r/min0.06mm
5. Check vibration, temperature and sound of bearing
parts.
0.04mm;
3. Bearing temperature: grease lubrication
80
Lubricating oil 70
6. Check whether tensioning regulation device is in Tension stress of chain is proper and
fastness or not during operation; regulate degree of tensioning regulation device can be
tightness of chain. regulated freely.
7. Dismantle contact switch of submerged scraper Chain breaking protection acts rightly and
conveyer, check whether chain breaking protection is is free from misoperation.
normal or not.
236
4.7 Slag Silo Major and Minor Maintenance Standard Items
4.7.1 Slag silo body and its accessorial devices overhaul
4.7.2 Clean ash and remove dirty for drainpipe and elements of slag silo
4.7.3 Flushing water pipe and its valves overhaul
4.7.4 Pneumatic slag discharging valve overhaul
4.7.5 Feeding water test
4.8 Overhaul Process and Quality Standard
Main working procedures
No. Item Quality requirement Note
and contents
1. It should be replaced of 1. When entering into
abrasion of silo wall silo for check and
1. Check and repair exceeds 2/3 of original work, related
abrasion, corrosion and thickness. regulations in section
Slag silo
crack of slag body. three Work in
body and 2. Silo body if free from
Vessels of chapter
its 2. Check and repair safety water leakage or slag
1 eight Pipeline and
accessorial and fastness of supporting leakage.
Vessel Overhaul
devices frame, supporting pole, 3. All supporting frame, (thermal and
overhaul ladder, guardrail and supporting pole, ladder, mechanical part) of
platform of slag silo. guardrail and platform of Working Safety
slag silo are safe and Regulation of Electric
reliable. Power Industry must
be executed.
1. Air cylinder surface is
free from rust and blow 2. When working at
1. Dismantle air cylinder,
spot. high altitude, related
replace piston sealing ring
regulations in chapter
and gland sealing ring; 2. Plane degree error of
thirteen High Altitude
clean, check and assemble. junction face of valve
Work (thermal and
plate and seat is lower
2. Check and replace mechanical part) of
than 1mm.
change sealing ring. Working Safety
3. Charge sealing ring is Regulation of Electric
3. Regulate clearance
free from air leakage and Power Industry must
Slag between valve plate and
other sealing rings are be executed.
discharging seat.
2 fine.
valve 3. Concentration of
4. Test slag discharging
overhaul 4. The clearance between acid in acid cleaning
valve and have the
valve plate and seat is pool should be not
tightness test of sealing
1mm3mm. too high and
ring.
generally controlled
5. Check, repair and 5. Slag discharging valve 2-3%.
regulate guide wheel of is with good agility and
4. When feeding
slag discharging valve, it sealing.
water to slag silo, it
should be replaced if
6. Abrasion of guide should be filled too
abrasion exceeds standard.
wheel diameter does not high, it is enough to
exceed 1mm. fill to middle of silo,
237
1. Check anchor bolts, 1. Anchor bolts, fixing and full silo is not
fixing bolts of ring hammer. bolts of ring hammer are allowed to avoid
complete and fixed. collapse.
2. Fill grease to bearing.
Vibrator 2. Grease is sufficient and
3 3. Check and replace motor
overhaul proper.
bearing.
3. See as in Submerged
Scraper Conveyer
Bearing Overhaul.
1. Return work permit 1. Silo body does not leak
ticket, fill dewatering silo water.
Feeding with water.
4 2. Sealing of slag
water test 2. Check water leakage of discharging valve is fine.
silo and tightness of slag
discharging valve.
5. Sewage Pump Overhaul
5.5 Overhaul standard items
5.5.1 Check that pump body and pump cover should be free from sand hole and crack, junction
surface should be smooth and free from scar.
5.5.2 Check that impeller should be free from steam corrosion, erosion and crack.
5.5.3 Check that bearing should be free from crack, damage and corrosion; screw threads part
should be complete and cooperation tightening stress with lock nut should be free from looseness.
5.5.4 Measure bending degree of pump bearing.
5.5.5 Clean and rinse all parts, replace sealing gaskets of all junction surfaces.
5.5.6 Check corrosion of pump pedestal and foundation.
5.5.7 Check inlet screen of water pump.
5.5.8 Check air control valve and replace sealing rubber gaskets.
Main working procedures and
No. Item Quality requirement Note
contents
1. Cut off power supply and throw off 1. Sealing wheel, impeller 1. Confirm
power supply cord. and volute chamber dismantling range
should be free from according to
2. Demount air control valve, outlet
distortion, crack and burr. check results,
check valve, check aging condition of
control
rubber sealing surface. 2. All parts should be
dismantling within
clean and complete.
3. Clean slag slurry in blowdown pit, minimum range
dismantle screen at bottom of suction 3. Bearing bending as much as
pipe, clean corrosion of screen. degree should be lower possible.
Overhaul after than 0.04mm.
1 4. Loosen connection bolts on flange 2. Marks must be
disassembling
surface of pump end cover, suspend 4. Quality requirement of done during
lifting ears of water pump motor with roller bearing see as in dismantling.
chain block and lift it away from water related chapter of
tank together with water pump rotor. Submerged Scraper
Conveyer Overhaul.
5. Clean all parts, check that impeller,
sealing wheel should be free from 5. Abrasion of bearing
steam corrosion, erosion, crack, sleeve and journal should
abrasion and corrosion. Check that be less than 2mm.
bearing should be free from crack,
238
damage and corrosion. Screw threads 6. Air control valve, outlet
should be complete; cooperation stop valve are complete
tightening stress with lock nut should and strict.
be free from looseness. Measure
7. Water tank is clean and
bending degree of pump bearing.
free from impurities.
6. Clean water tank and water pump
volute chamber, check that pump body
and pump cover should be free from
sand hole and crack. Junction surface
should be smooth and free from scar.
Check that volute chamber should be
free from scar and damage. Measure
cooperation clearance with impeller.
Chapter Dry Ash Transportation Equipments Overhaul
1. Applicable range: this regulation is applicable for dry ash transportation equipments overhaul
and maintaining of Indonesia Paiton 1660MW coal fired thermal power plant.
2. Quoted standard
DL-T748.92001 Guide of maintenance of boiler unit for thermal power station Part Nine: Dry
ash transportation system overhaul
GB150-89 Steeliness Pressure Vessel
DL647-1998 Maintenance code for boiler and pressure vessel of the power industry
DAS1994227 Working Safety Regulation of Electric Power Industry (thermal and mechanical
part)
3. Brief introduction
3.1 System brief introduction
Pneumatic ash handling adopts positive pressure pneumatic ash transportation system.
Flying ash from ESP is transported to ash silo for storage, filled with water, regulated to be wet and
then transported ash yard for grinding and pressing for storage, or it is loaded by dry ash bulk
machine and then transported for comprehensive utilization. One set of pneumatic ash handling
system is set for each unit.
Each field of ESP has eight (8) ash hoppers. Eight (8) ash transporters are arranged in a
group in field one, ash in which is transported to coarse ash silo through a 125 pipeline. Ash
transporter is 80/12/10 type MD pump with cubage of 2.26m 3. Twenty four (24) ash transporters of
field two, three and four are arranged in a group, which connects to a 125 pipeline that
transporting to ash silo. Ash transporter is 45/8/8 type MD pump with cubage of 1.27m3.
A ash storage silo with diameter of 9m is set in power plant with effective cubage of 500m3,
which can meet the storage requirement of 24-hour discharging ash amount when the unit is
running with full load. A bag type dedust filter is set on top of each ash silo to avoid polluting
environment due to removing exhausted air in ash silo.
Two kinds of ash discharging are also set under ash silo, one dry ash bulk machine with
output of 100t/h is installed for sealing tank car transporting ash for comprehensive utilization; one
wet mixer with output of 100t/h is set, which regulate dry ash to be wet, and then the wet ash is
transported to ash yard by automatic unloading truck.
To ensure smoothness of ash discharging in ash silo, gasification air system is set in ash silo,
which has two groups of gasification air fan and electric heater. The heated air is supplied to
gasification plate at bottom of ash silo and then enters into material layer for assisting in
239
discharging ash.
High level indicator, low level indicator and continuous level indicator are set for each ash silo
and are arranged on top of ash silo for displaying levels in silo.
3.2 ESP ash handling system
3.2.1 Ash discharging amount of an ESP ash hopper is 191t/h when boiler burns design coal with
BMRC;
3.2.2 Ash discharging amount of an ESP ash hopper is 11.46t/h when boiler burns checked coal
with BMRC.
3.2.3 ESP ash discharging temperature: 120

3.2.4 Net height under ESP ash hopper: 4.0m.
3.4 Pneumatic transportation arrangement parameter
In ESP ash handling system, one (1) transportation pump is equipped under each ash hopper
in field one, one (1) piece 125 ash pipe is set; one (1) transportation pump is equipped under
each ash hopper in field two, three and four, one (1) piece 125 ash pipe is set. Ash transportation
pipe transports dry ash to ash silo, one (1) ash silo is equipped with effective cubage that can store
24-hour produced ash when boiler is in BMCR. Inner diameter of ash silo is 9m; twelve (12)
gasification grooves are set for each ash silo. Two discharging outlets are set at bottom of ash silo,
one connects to dry ash bulk machine and the other connects to wet mixer. Extension distance of
material outlet is 3000mm. One (1) bag type dust catcher is set on top of ash silo.
Two (2) air compressors are set in transportation air compressor system, one is running and
the other one is in standby; transportation air compressor adopts oil spraying screw type. Air
compressor output: flow Q=17.5Nm3/min and pressure P=0.75MPa. Front filter, combined type
dryer, postposition filter flow Q=20N m3/min, pressure =0.8MPa; Q=13.06 m3/min, P=58.8KPa.
Electric heater power N=50kW. Two (2) gasification air fans are set for each boiler, one is running
and the other one is in standby. Electric heater is set for ash hopper, every ash hopper has two
gasification plates and specification of each plate is 150mm300mm. Sixteen (16) electric heating
plates are set for each hopper with four (4) in each direction, Q=13.06 m3/min and P=58.8KPa.
Electric heater power N=50kW.
Ash silo high level indicator for supervision and alarming is set for ESP and low level indicator
of field one and two is set on dry ash transporter.
Ash silo is with nice insulation measures and adopts electric heating type to make wall
temperature of ash hopper be no lower than 120 and 510 higher than gas dew point
temperature. Constant temperature device is set for electric heater to keep electric heater running
safe and reliable.
High level indicator, low level indicator and continuous level indicator are set for ash silo; one
(1) set of bag type dust catcher is set on top of ash silo, air after purification is discharged into air
directly.
3.4.1 Silo pump
Positive pressure and dense phase pneumatic transportation system cuts materials in
pipeline into section of material and air through impulse pneumatic force; it uses static differential
pressure at two ends of material to push material to move. The hardcore of dense phase
pneumatic transportation system is a storage type pneumatic sending pump.
Silo pump consists of silo body, butterfly valve, vent valve, material feeding inlet and air
pipeline. Protuberant air nozzles inside cone makes gas produce vortex; with the increase of
pressure inside sender, materials to be sent flows in vortex, which realized successful material
transportation. Quite low air pressure can realize low speed and high concentration transportation.
Its working procedure is as following:
a. Level indicator inside ash hopper has not been covered, inlet dome valve is closed and
240
sealed, it does not consume air at this time.
b. When any level indicator of ash silo in the same group is covered, system touches off, inlet
dome valve of silo pump opens, material inlet timer starts timing and keeps a set time to make ash
drop into silo pump.
c. Once set time finishes, inlet dome valve closes, add pressure to sealing ring for sealing and
confirm sealing is normal through pressure switch. Then inlet air valve of main transporter opens,
compressed air transports ash from silo pump to ash silo.
d. Pressure transmitter is set on air inlet pipeline, when detecting that pressure in pipeline has
decreased to a certain value, close compressed air inlet valve, system recovers. Following is the
next circulation.
2 4
3
141
1 2 3
4 5
English
Control air source
Air control box
Main transportation air source (only main pump has)
Auxiliary transportation air source
Next pump
141 Fig. 1-4-1 Silo pump structure diagram
Manual flashboard valve
Material inlet dome valve
Vent dome valve
Silo pump level indicator
241
Material outlet dome valve
MD pump is applicable for middle output, middle & long distance centralized transportation
and is pressure type silo pump. Each pump includes: air inlet subassemblies, flexible connector,
material inlet dome valve, vent dome valve, outlet dome valve (only outlet pump has), shell and air
line connection fittings (including pneumatic inlet valve, filter, orifice plate, check valve etc.).
Little Amount And Many Times principle is adopted for transportation mode to strengthen
emergency storage capacity of ash silo. Because Little Amount and Many Times principle is
adopted, material low level indicator is installed very low to make ash stay in ash silo shortly, ash
silo is always in empty state. Thus, if the system is in fault, ash silo has the capacity of
8-hour-storage. This not only gets times for maintenance, but also cushion the direct influence to
dust catcher. Beside, the running characteristics of Little Amount And Many Times has also
greatly decreased heat lose and hardening of ash in ash silo.
Due to Little Amount And Many Times principle, which makes ash transportation amount
quite little for one time, but transportation times are quite more within same time; thus, relative
small silo pump is selected under ash hopper of ESP and material inlet valves diameter grade
decreases correspondingly. Because transport ash once more, valve on pipeline should be
opened and closed once more, and it leads once more abrasion and once less of life; thus, it
requires higher requirements of the valves in ash transportation system. The adopted valve is
called dome valve, which is important part in ash transportation system. Dome valve is a special
valve developed at the beginning of 1970s by Macawber subsection of Clyde Bergemann
Company for ash handling. It is casting shell structure, two rotating bearing with rotatable cast iron
dome are installed inside. Material inlet valve element is a spherical surface; during opening and
closing material inlet valve, 1mm clearance between valve element and valve body seal should be
ensured to make valve element run with no contact. There is no friction produced between valve
element and valve body. Under the state that material inlet valve is in sealing, rubber sealing ring
will be charged and expands and cling spherical valve element tightly to reach sealing effect. Once
when valve gets signal of start, rubber sealing ring will release pressure to make valve element
turn and start under state of no touch. Meanwhile, dome valve is also with function of supervising
sealing pressure and alarming; that is, when sealing air pressure can not be formed or sealing air
pressure is low, it shows that charge sealing ring of dome valve leaks, the system will alarm to
remind maintenance personnel to change sealing ring. Due to individual and special design, dome
valve has following characteristics:
1. Simple structure and reliable work.
2. Agile open and close, it can cut off dynamic and static material column.
3. Firm pressure sealing may formed when it is closed.
4. Be able to bear 0.8MPa.
5. Be able to bear -20130.

6. Long life and little maintaining work.
7. When pneumatic ash handling is running normally, sealing ring life is more than 1 year.
8. Material in chamber flows with no block.
Dome valve is controlled by power to open or close. When unit is running with low load, ash
amount produced within unit time is relatively small; a material filling time is set to make ash not
stay in silo for too much time, the set value is 900s. No matter ash silo is full or not, only 900s is
permitted for dropping material, material inlet valve must close to stop material filling and execute
fluidizing and transportation when time is finished. When unit is running with high load and the silo
is getting in less then 900s; under this condition, control material dropping through material level
indicator installed on silo pump. When high level indicator installed on silo pump is touched off by
flying ash, material dropping dome valve will lose power and closes and then execute the following
procedure. All as above, two values are set logically to control material dropping dome valve, their
relationship is OR; thus, it should not wait for long time due to low load and it should not make silo
242
pump be too full while set time is finished due to high load, which leads satisfactory result of
material dropping. MD pump working state is as fig. 1-4-2 (take four silo pump in one group of field
one as an example):
3.4.2 Dome valve is a ball valve taking hemispheroid as valve element, usually adopts
driving and is mainly used for cutting off or transferring on air-solid phase pneumatic conveying
pipeline. During action of closing or opening of dome valve, there is 3mm clearance between
hemisphere valve element and shell; thus, there will be no block even under condition of high
temperature hot expansion. When valve closes, hollow charge rubber belt installed in valve shell
groove will cling hemisphere under force of charging pressure, which produces nice sealing effect.
When dome valve is open or during dome valve action, charging rubber belt is not be charged
with compressed air, it draw back to its groove by elasticity of itself, it will not be eroded by
air-solid phase pneumatic conveying and its flow will not be influenced.
Dome valve design pressure is 0.8MPa, air cylinder working pressure is 0.40.6MPa,
rubber belt charging pressure is about 0.6MPa and its temperature resistance is 130.
Commissioning of dome valve: under air pressure of 0.4MPa, action of open and close of dome
valve should be agile and reliable; when valve is at close position, hollow rubber belt is charged
with 0.6MPa compressed air, rubber belt should be free from leakage; have the air tightness test
with 0.8MPa to valve, valve element should be free from leakage. Before action of opening of
valve, control mechanism of valve should release charging pressure inside rubber belt
automatically; rubber belt should draw back automatically and be no higher than inner surface of
valve body. Check and Commissioning of journey switch should be done synchronously.
See as in Fig.a: when silo pump is at state of filling material, both ash silo and silo pump level
indicator have not been covered; material inlet valve and vent valve open when power is sent, silo
pump is at material inlet state, this time outlet dome valve closes.
When one or more high level indicators in silo pump are covered or material inlet timing is
finished, material inlet valve and vent valve closes. At the same time, inlet valve transporting
compressed air and outlet dome valve open and start to transport ash. After ash transportation,
transportation compressed air inlet valve closes.
3.5 Ash silo and ash discharging equipment
3.5.1 Ash silo brief introduction
3.5.1.1 Ash silo type and structure
Ash silo lies at end of ash handling system; it is a common facility of pneumatic ash handling
system and with functions of collecting and storing discharged material. Transfer ash silo is close
to ESP. It main function is to collect dry ash and store it for a short time for the convenience of
transporting outside of power plant by other equipments, systems or facilities.
Transfer mode of dry type ash handling usually contains:
1Dry type direct transfer: Transfer dry ash outside of plant or to ash transporter by using
pneumatic ash handling mode or mechanical transportation mode.
2Transfer after regulating dry ash to be wet: Mix dry ash with water to be wet ash (water
content is 15%-30%) by mixer, then transfer wet ash to ash yard by ash transportation car or other
mechanical transportation mode.
Ash silo is generally divided into four build layers from up to down: silo top layer, silo chamber
layer, mechanical layer and silo bottom layer. Silo top layer mainly consists of dry ash separation
device, such as cyclone separator, impulse bag type dust catcher, and exhausted air bag type dust
catcher. Beside, vacuum pressure relief valve, level indicator, air distribution box and pipe transfer
valve are also equipped.
Silo chamber is ash storage silo; one ash silo is set in power plant and is steel cone bottom
type. Its diameter is 9m, its cubage is 500 m3, silo bottom is taper shape. In order to discharge
dry ash out from ash silo smoothly, many gasification flumes are arranged in radiation.
243
Electric air lock, bulk machine or wet mixer, maintenance platform and local control device are
installed at mechanical layer. Silo bottom layer is zero meter layers and also channel for
transporting ash outside.
3.5.1.2 Silo bottom equipments
Wet ash discharging system includes hydraulic mixer, dry ash valve and electric feeder.
Dry ash valve adopts anti=abrasion dome valve.
Electric feeder sealing is strict and free from flying ash, block pipe should be set to avoid
fleeing upwards that may result in ash knotting on dry ash plate, multi-blades rotary impeller is
adopted, lock air cavity is multi-piece double-layer air locking structure, sealing between impeller
and shell is strict.
Filling water mixer is also called wet mixer, which is installed on working platform at bottom
of ash silo and used to regulate and mix dry ash into wet ash by filling proper water for the
convenience of transportation by great tonnage automatic unloading car.
Double-shaft mixer adopts horizontal arrangement, two vis-a-vis revolving shafts driven by
motor are set in long groove with section of flat U, impellers with a certain obliquity or spiral angle
are installed on the shafts; after entering into mixer and under forcible mixing and boosting by
revolving impellers, powder coal ash mix with water mist sprayed out from upper atomization
nozzles, mixing while boosting, which completes the continuous process of blending, mixing and
discharging. Impeller feeder is generally equipped at material inlet of double-shaft mixer for
evening inlet material one hand and for regulating output or humidity one the other hand. Water
supplying regulation valves are also equipped for double-shaft mixer to regulate humidity.
3.5.2 Dry ash unloading system
Dry ash unloading system consists of dry ash bulk machine, motor-driven feeder, pneumatic
dry ash valve, pneumatic vent valve, duct suction air fan and material level indicator.
Expansion tube of dry ash bulk machine adopts double bushing structure, its inner pipe
adopts high quality, anti-abrasion manganese steel plate, which makes it high abrasion resistance
and a long life; outer pipe adopts silica gel fine sailcloth. Dry ash bulk machine level indicator
adopts solid tuning fork switch, which can control the level rightly and sensitively and be free from
misoperation to ensure stop feeding material automatically when tank car is full. Dry ash valve is
equipped for dry ash discharging system, it can be closed can opened freely with strict sealing; its shell
is made from anti-abrasion material, valve plate adopts stainless steel plate. Sealing stuffing material
adopts anti-aging, anti-abrasion, fine lubrication and good flexibility graphite. Solenoid valve equipped
for pneumatic valve should be waterproof and dustproof.
Electric feeder equipped for dry ash discharging system turns freely and adopts multi-blade
revolving impellers; air lock cavity is multi-piece double-layer air lock structure. The sealing
between impeller and shell is strict and material is filled evenly; shell is equipped with check hand
hole.
Local control box is equipped for dry ash discharging device, which is equipped with
semiautomatic control and automatic control discharging function, and interlocked with pneumatic
dry ash valve and electric feeder at inlet.
Specific operation process of dry ash discharging device is:
1. Carrying car is perched; contraposition of bulk head and material inlet adopts
semiautomatic control mechanism, control and low down bulk head, start automatic control
function after contraposition.
2. Sequence of automatic control during discharging material is:
a. Open pneumatic vent valve on vent-pipe;
b. Start dust suction air fan;
c. Open pneumatic dry ash valve at inlet of bulk machine;
d. Start electric feeder to fill material to carrying car.
244
When material tank is full, level indicator on bulk head sends signal, then pneumatic dry ash
valve and feeder (about 46s) stops automatically; Suction air fan stops, bulk head raises
automatically, which a complete discharging process is done.
Pneumatic dry ash valve, pneumatic vent valve and dust suction air fan are locked from each
other when at the two actions of starting feeding and fully fill, that is when the former action is in
execution, the latter equipment can not be started or closed. Interlock must be released if do not
execute in above sequence. Necessary alarm signals are equipped for control box of dry type
discharging device to display and detect running or failure status of the equipment, signal
interfaces for remote ash handling control room should also be preserved.
Dry ash discharging head is generally installed on working platform at bottom of ash silo
together with wet mixer, which is also can be installed at silo side to supply material to bulk tank
car for the convenience of transportation to cement factory for comprehensive utilization.
Dry ash discharging head is a telescopic sleeve type flexible discharging pipe with ring type
jacket, its middle part is for discharging; its jacket part is for venting; upper section is material inlet
connected with discharging hopper in silo; valves are installed in middle part; lower part is
discharging outlet that aims at inlet of tank car to discharge material to tank car; vent interface is
set at side face of upper part on discharging head and is connected to inlet of dedust air fan
through pipeline together with dry ash discharging head. Exhausted air is introduced into ash silo
from its top by dedust air fan; after filtering in bag type dust catcher on top of silo, exhausted air is
discharged into air. The powder dust left behind is preserved in ash silo together with dry ash
transported by pneumatic transportation equipments such as silo pump. Generally one check
valve is connected in series on vent pipe to avoid ash & air flowing backwards to dedust air fan dry
ash discharging head when pneumatic ash handling system is in operation. Besides, a double-line
windlass is equipped for dry ash discharging head to control height of discharging outlet for
supplying tank cars with different tonnage and inlets; meanwhile, discharging head can be lifted to
avoid damaging when tank cars pass in and out. Also, discharging head can be inserted into tank
car inlet to avoid overflow when tank car is full. Signal of Material Full can be set according to
actual requirement to make the device send signal automatically to close inlet valve when tank is
full, which avoids overflow when tank car is full.
When tank car is positioned under dry ash discharging head, discharging outlet of the head
aims at inlet of tank car brought by windlass, then discharging starts. Start dedust air fan, open the
inlet valve between discharging head and discharging hopper of ash silo, powder coal ash flows
out from ash hopper and then flows into tank car through discharging pipe in the middle of
discharging head; dusty air overflowed from tank car is sucked into ring type jacket between
flexible sleeve and discharging pipe by negative pressure produced by dedust air fan, and then
discharged into ash silo through dedust air fan. After tank car is full, signal of Material Full is sent,
inlet valve closes automatically, windlass lifts discharging head and the fully filled tank car leaves
away. Then, the waiting empty tank car is going to do the next circulation.
3.5.3 Pneumatic ash transportation system process
Air Dryer Air Bag type dust Vent to air
compressor storage catcher
tank
Flying Silo Ash silo Wet mixer Ash tank Ash yard
ash pump car
Dry ash bulk Ash tank User

machine car
245
Pneumatic ash transportation process flow diagram
3.6 Pneumatic Ash Handling System Specification
3.6.1 Equipment Parameter
3.6.1.1 Supplying water and instrumental air parameter
System Water or compressed air Flowm3/h PressureMPa
Economizer ash Water/compressed air 2.88/0.4 0.3/0.55~0.6

ESP ash Compressed air 1.8 0.55~0.6
Wet mixer Water 30 0.3
Transportation air
compressor Water 12.5 0.3
Freezing type dryer Water 5.92 0.3
Ash silo area Compressed air 0.27 0.55~0.6
3.6.1.3 ESP field one
1 Quantity 8 sets for each boiler
2 Model 80/12/10 type MD pump
3 Cubage 8 x 2.26 m3
B-MCR 56
4 Output t/h
Design output 88
5 Working pressure <0.3 design value0.7 MPa
6 Working temperature 200

7 Pneumatic ash inlet valve DN300 pneumatic dome valve
8 Pneumatic ash outlet valve DN250 pneumatic dome valve
9 Balanced valve type none
10 Vent valve type DN80 pneumatic dome valve
11 Valve plate material/life Cast iron/80000 h
12 Sealing ring material/life Fluorin rubber/16000 h
Transporter shell
13 GB713-86 stage 20g/8 mm
material/thinkness
14 Weight 2080 kg
15 Manufacturer Clyde company
3.6.1.4 ESP field two
B-MCR 10.88
4 Output t/h
Design output 54.4
246
Working
6 200
temperature
Pneumatic ash DN200 pneumatic dome
7
inlet valve valve
Pneumatic ash DN220 pneumatic dome
8
outlet valve valve
Balanced valve
9 none
type
DN50 pneumatic dome
10 Vent valve type
valve
Valve plate
11 Cast iron/80000 h
material/life
Sealing ring
12 Fluorin rubber/16000 h
material/life
Transporter shell
13 GB713-86 stage 20g/8 mm
material/thickness
14 Weight 1500 kg
3.6.1.5 ESP field three
B-MCR 2.18
4 Output t/h
Design output 10.88

Transporter shell
12 GB713-86 stage 20g/8 mm
material/thinkness
13 Weight 700 kg
3.6.1.6 ESP field four
247
Field four: B-MCR 0.435
Design output 2.176
4 Output t/h
Field five: B-MCR 0.109
Design output 0.435

Transporter shell
12 GB713-86 stage 20g/8 mm
material/thinkness
13 Weight 700 kg
3.6.1.7 Ash silo equipment
3.6.1.7.1 Ash silo
Single
1 Quantity: 1
boiler
2 Effective cubage of ash silo t

Geometric volume of each ash
3 500 m3
silo
4 Effective volume of each ash silo 3300 m3
Ash silo dimension(inner
5 11500X9200X26000 mm
diameter x height)
Gasification plate dimension and
150X300 mm
length
6
Gasification plate quantity 12
Manufacturer Sizhou Electric Power

Height between bottom layer
7 9 m
and operation layer
Pressure vacuum relief valve
8 508
type
Check hole(dimension and
9 3 x 800 mm
quantity)
Requirement for connection
10 Yes
platform between ash silos
11 ash silo total height 1876 m
12 level high, low level indicator Each for one Set
248
indicator Continuous level
1 Set
indicator
Impeller diameter 400 mm
Pool dimension 4x2x3 ( length x width x depth) m
Bearing length 2.5 m
13 Mixer Quantity 1 Set
Rotating speed 85 r/min
Motor type Y132S-4
Power 5.0 kW
3.6.1.7.2 Bag type duster
single
1 Quantity 1
boiler
Impulse counter blowing DMC144-II

2 Type
for ash silo
3 Filter area 108 m2
4 Impulse soot blowing air flow 0.41.7 m3/min
Impulse soot blowing air

5 0.5~0.7 MPa
pressure
6 Dust removing efficiency 99.5%

7 Exhaust fan air amount 7950~14720 m/h
8 Filter bag dimension 140 m2
Filter bag quantity and
9 144 bags / 120X 2000 mm
dimension
10 Filter bag material Nomex
11 Filter bag air transmittance rate 12:1
12 Filter resistance 1176~1470 Pa
13 Filter air flow speed 0.8 m/min
14 Life 10000 h
15 Duster shell material Carbon steel plate
16 Equipment dimension 5700X2200X2750 mm
17 Air fan motor power 2X7.5 kW
18 Manufacturer Sizhou Electric Power
3.6.1.7.3 Humidification mixer
1 Quantity 1 single boiler

2 Type SJ100A.0
3 Output 100 t/h
249
4 Required water pressure 0.40.6 MPa
5 Ash humidity after watering 15~25%

6 Blade material Wear-resistant alloy cast steel
7 Bearing material GCr15SiMn
8 Motor power 22 kW
9 Coupling type Cross sliding coupling
10 motor/speed reducer type Y200L2-6/XWD22-9-17
11 Water consumption amount 20~30 t/h
Water inlet manual regulating
12 PN1.0DN50
valve
Water inlet pneumatic butterfly
13 PN1.0DN50
valve
Supporting Type SBMc-300.0
manual
14 Inlet, outlet
flashboard DN300 mm
valve specification
Type QBM-300.0
Supporting
pneumatic Inlet, outlet
15 DN300 mm
flashboard specification
valve
Air source 0.4~0.6 MPa
Type DSG-450.0
Output 100 t/h
Supporting Inlet, outlet
450X450 mm
16 electric specification
feeder
Motor/speed reducer
Y132S-4/XWD3-5-1/23
type
Power 3.0 kW
3.6.1.7.4 Dry ash loading machine
1 Quantity 1 single boiler
2 Type SZJ100.0
3 Output 100 t/h
4 Outlet expansion distance 1800 mm
5 Inlet dimension 159
6 Outlet dimension 159
7 Bulk head movements
8 Lifting motor type YEJ90S-6
9 Lifting motor power 0.75 kW
10 Level indicator type Solid tuning fork
11 Supporting Type SBMc-300.0
250
manual
Inlet, outlet
flashboard DN300 mm
specification
valve
Type QBM-300.0
Supporting
pneumatic Inlet, outlet
12 DN300 mm
flashboard specification
valve
Air source 0.4~0.6 MPa
Dry ash bulk machine dedust and ash silo share one bag type dust catcher.
3.6.1.7.5 Motor-driven feeder
1 Quantity 12 Set
2 Output 150 t/h
3 Working temperature 200 C
4 Inlet material particle diameter 5 mm
5 Inlet dimension 600 x 600 mm
6 Rotating speed 1440 m/min
Model Y132S-4
Power 5.5 kW
7 Motor
Voltage 380 V
Manufacturer
4. Overhaul Items and Process Quality Requirements
4.1 Overhaul items
a. Repair air system, mainly check air regulation valve, check valve etc.
b. Dismantle and check abrasion of gasification nozzle, material outlet tee; replace damaged
nozzles;
c. Replace manhole gasket.
4.2 Dry fly ash bulk machine overhaul item
a. Check dilapidation condition of bulk head, expansion joint, sleeve hoop, steel wire rope,
and rope clip and pulley assembly group.
b. Dedust air fan overhaul (see as in Centrifugal Air Fan overhaul in Ash Silo Equipment
Overhaul Specification)
c. Speed reducer overhaul (see as in Idler Wheel Swinging Reducer in Slag Removing
Equipment Specification)
Name Content Process point Quality requirement
1. Close inlet flashboard valve and
Preparation make sure that material in silo is Strict and free from
Silo pump discharged completely.
for overhaul leakage
2. Close air check valve.
251
1. Check and regulate flow, pressure 1. Regulation valve can
regulation valves. regulate changed
parameters rapidly with no
2. Check non-return valve, replace it
delay.
Air system if sealing is not fine.
overhaul 2. Non-return valve is strict
3. Check gasification performance of
and reliable.
fluidizing device.
3. Fluidizing plate breathe
freely and evenly.
Material inlet
valve and See as valve overhaul
See as valve overhaul chapter
outlet valve chapter
overhaul
Check valve action Valve switch is at right
Silo pump trial
position and its action is
run
normal.
1. Check and replace dust collecting 1. Strict and free from
bag with dilapidation and ash leakage
leakage.
2. Framework is complete
Check and 2. When replacing dust collecting and two ends are fixed and
replace dust bag, upper and lower tightening reliable.
collecting bag rings should be loosened firstly,
dismantle old dust collecting bag;
new bag should be in free sag after
installation, check that framework is
Dry fly ash free from block.
bulk 1. Clean rope guider and oil dirty on 1. Clean oil dirty.
machine shell.
2. Rope guider is complete
2. Check that rope guider and steel and steel wire rope is free
Check
wire rope are free from crack or from dilapidation or
motor-driven
dilapidation. foul-up.
hoist
3. Regulate limit 3. Journey switch is
reliable and journey
complies with requirement.
Check level It should be replaced when level Material level indicators
indicator indicator is unreliable. action is reliable.
Demount chain, chain wheel; align Chain and chain wheel is
Demount
the dismantled chain wheel, no free from damage.
chain wheel
forceful dismantling is allowed.
1. Open manhole to clean ash. 1. Clean ash.
2. Demount blocked nozzles and 2. All the nozzles are
smooth them. smooth and with good
Double-shaft Check inside atomization.
3. Check abrasion of sleeve wall and
mixer
scraper. Weld the sleeve wall with 3. Sleeve wall and scraper
abrasion by replacing; replace the are free from abrasion or
abraded scraper with distortion. distortion.
Assemble in sequence of mixer, rear Four anchor bolts should
Assemble feeder and gate valve. be in same plane and
whole unit windage should not
exceed 5mm.
252
Trial run After all recovered, send power for It turns stably and free
trial run. from block.
Chapter ESP Machinery Equipment Maintenance
1. Applicable range:
This regulation is applicable for ESP overhaul and maintaining of Indonesia Paiton 1660MW
coal fired thermal power plant.
2. Quoted standard:
DL-T748.62001 Guide of maintenance of boiler unit for thermal power station Part Six:
ESP Overhaul
GB/T13931-92 ESP performance test method
JB5910-91 ESP technical conditions
JB5906-91 General technical conditions of C type anode plate of ESP
JB5907-91 General technical conditions of rapping system of ESP
JB6407-92 Technical specification of ESP commissioning, operation, maintenance
and safety
JB/T5911-91 Technical requirement of welding piece of ESP
GB/T1393192 Guide rules for construction process of ESP
GB/T1393192 ESP installation and detection

ZBJ88008-89 Technical conditions for machinery installation of ESP
3. Model: 2SY345M-288-140, Type: Horizontal Type, Plate Type and Dry Type
No. Item Unit Quantity
Design efficiency % 99. 5
1 Ensured efficiency (one electric field stops) % 99.70
Checked coal efficiency % 99.65
2 Body resistance Pa 200
3 Body air leakage rate % <2.0
4 Noise dB <85
Channels quantity of electric field (1) Piece 240
Homopolarity distance of electric field mm 400
Effective length of each electric field m 4.52+4.02
5 Effective total length of four electric fields m 17
Effective width of electric field m 18 (single room
Effective height of electric field m 15

2
Total dust collection area (each boiler) m 135000
2
6 Effective section area m 480
7 Proportion of length and width 1.13
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8 Chamber quality 2
9 Electric field quantity 4
10 Anode plate type 480C
11 Total effective area of anode plate m2 40800
12 Anode plate material SPCC
13 Cathode ray type Needle arista
14 Total length of cathode ray m 55800
15 Cathode ray material SPCC
Specific ash collection area (maximum gas
16 m2/m3/s 78.44
amount)
Specific ash collection area when one
17 m2/m3/s 73.53
electric field stops
18 Drive speed cm/s 6.60
19 Drive speed when one electric field stops cm/s 6.58
20 Gas flow speed m/s 1.085
Shell Negative pressure KPa -8.7
21 design
Positive pressure KPa +8.7
pressure
22 Shell material Q235
23 Ash hopper quantity of each boiler Piece 32
24 Hopper electric heating type Electric heating
Rectifying transformer quantity equipped
25 Set 8
for each boiler
Oil immersed self-cooling/

26 Rectifying transformer type and weight t
1.8
GGAj02-2.0A/72KV 8 set
Rated capacity of each rectifying
kVA 206
transformer
27 Rectifying transformer input voltage V 380

Rectifying transformer input current A 541
Rectifying transformer output voltage kV 72
Rectifying transformer output current A 2.0
Applicable height above sea level and 1200
28 environment temperature of rectifying m,
transformer +40-40
29 Total electric load (each boiler) kVA 3800

30 Maximum running load (each boiler) kVA 1600
Heat insulation material and cubage
31 m3 Mineral cotton,1400
(including ash hopper, gas box)
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Efficiency corrected curve
. Corrected parameter of inlet dust content
. Gas amount correction coefficient
. Inlet gas temperature correction

32
coefficient
. Correction coefficient of sulphur content

in fuel
Correction coefficient when one power

supply area stops
4. ESP Body Common Faults Analysis and Countermeasures
4.1 ESP electric field fault analysis and countermeasure
Fault Reason Analysis Countermeasures
1. Cathode ray ruptures due to fatigue 1. Stop boiler to replace it or clean the
under impulsion of electric field force or broken ray, improve manufacturing
burned to be broken under effect of quality of cathode ray. Regulate rapping
electric arc, which results in short circuit. cycle reasonably to restrain electric arc.
2. Fixing bolts or nuts of cathode ray 2. Stop boiler to replace it or clean the
drop, which make cathode ray and anode dropped cathode ray, improve welding
plate be in short circuit. tension and quality of bolts and nuts.
3. Anode plate does not expands 3. Stop boiler to check expansion
smoothly after heating and distorts, which clearance and distortion of all anode
makes cathode and anode be on short plate, correct the distorted plate,
Electric circuit. regulate or cut the insufficient
field is in clearance.
complete
short circuit 4. Deal it as the method dealing with
4. Full ash hopper causes electric field
ash hopper blocking.
short circuit.
5. Stop boiler, look for and clean
impurities.
5. There is metal eyewinker between
cathode and anode in electric field, which
results in electric field short circuit. 6. Deal it as method dealing with HV
insulation part.
6. Dew formation or ash accumulation at
supporting insulator, insulation sleeve,
PTFE ash baffle and cathode rapping
porcelain shaft cause short circuit.
1. Insulation performance of HV 1. Deal it as method dealing with HV
insulation parts decreases, which causes insulation part.
arc discharge.
Electric 2. Stop boiler, look for and clean
field is in 2. There is cotton thread, welding rod, impurities.
incomplete wooden scraps or ash block in electric
short circuit field.
3. Stop boiler to replace it or clean the
3. Cathode ray lower part drops or is
broken ray, improve manufacturing
swinging with ray broken.
quality of cathode ray.
255
4. Clean the fault as per method of
treating ash hopper blocking and
4. Ash hopper is full or ash is seriously
cathode & anode rapping.
accumulated at cathode and anode,
which builds an ash bridge.
1. Intension of jointing of anode plate is 1. Orientate anode plate again,
not sufficient, which causes reinforce anode plate and jointing
displacement; positioning pin shaft quality of orientation baffle, replace the
ruptures and results in excursion. broken orientation pin shaft.
2. Hot expansion between anode and 2. Stop boiler to check, it should be cut
cathode plates is not smooth, which at site if expansion clearance is
makes distance between different poles insufficient to ensure all expansion
of electric field shorten. clearances comply with design
Distance requirements.
between 3. Cathode ray loosens, hot expansion
different meets resistance; cathode ray bends and 3. Stop boiler to replace or clean
poles of distorts. loosened or distorted ray.
electric 4. Bolt tension or jointing tension of fixing 4. Stop boiler to repair, repairing
field cathode small frame is insufficient, which welding should be done for loosened
shortens makes small frame loosen and displace. small frame; reinforce jointing intension.
5. Cathode, anode rapping shaft (stem) 5. Stop boiler to clean rapping fault,
displaces and rap eccentrically, which correct the eccentric hammer, correct
makes anode plate and cathode small twisted and distorted anode plate and
frame distort and twist. cathode frame.
6. Ash accumulates seriously on plates 6. Eliminate anode, cathode rapping
and ray. system fault or regulate rapping cycle
again.
1. Polar distance in electric fields 1. Deal with it as per fault of polar
fluctuates and changes. distance shortens.
2. HV power supply control 2. Regulate HV power supply control
characteristics have not been regulated characteristic.
Sparkle in
well.
electric 3. Regulate rapping cycle again.
field 3. Rapping cycle of former electric field is
4. Regulate rectifying transformer tap
discharges too short.
again,
frequently
4. Rectifying transformer tap regulates
5. Inform boiler operators to improve
improperly.
operation conditions.
5. Boil working condition changes and
gas condition fluctuates greatly.
4.2 Anode plate fault analysis and countermeasures
1. Gas temperature is too high or 1. Stop boiler to check, it should be cut
expansion clearance is small, which at site if expansion clearance is
causes bending and distortion due to insufficient to ensure all expansion
unfree expansion of the plates. clearances comply with design
Distortion of requirements.
anode plate 2. Anode plates do not joggle well,
orientation baffle displaces, orientation 2. Stop boiler to check parts in fault,
pin shaft ruptures and it raps eliminate fault of non-joggling,
eccentrically, which causes distortion of dropping, broken pin etc; correct
the plates. anode plate.
Displacement Intension of orientation jointing and Orientate anode plate again, reinforce
of anode orientation baffle is insufficient, which anode plate and jointing quality of
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plate causes displacement. orientation baffle, replace the broken
orientation pin shaft.
1. Anode rapping machine is in fault and 1. Deal with it as per method of dealing
its rapping force is small. with anode rapping machine fault.
2. Deal with it as per method of dealing
with anode rapping control device
2. Anode rapping control device is in
fault; if rapping cycle is too long, stop
fault or its rapping cycle is too long.
time of rapping should be shortened.
Serious ash
3. HV power supplying equipments are
accumulation
3. Oil film is adsorbed on anode plate, not allowed to be put into operation
of anode
dust specific resistance is high with high when boiler burns fuel oil. Method of
plate
viscidity, which makes it difficult to clean Intermittent Power Supply or Rapping
ash. when Electric Field Stops should be
adopted for high specific resistance
powder dust. Compressed air should
be used timely to clean accumulated
ash in electric field to ensure
cleanliness of plate surface.
4.3 Cathode ray and small frame analysis and countermeasures
1. Mechanical intension of cathode ray is 1. High mechanical intension cathode
insufficient and mechanical fatigue and ray should be adopted, replace or
Cathode ray rupture occurs to cathode ray under clean broken polar rays.
breaks, impact of rapping force.
loosens and 2. Improve installation quality and
drops 2. Intension of bolts and nuts is jointing intension, replace or clean
insufficient and cathode ray loosens dropped polar rays.
under impact of rapping force.
Cathode ray Hot expansion of cathode ray is unfree, Improve installation quality, repair or
bend and which causes bending and distortion. clean the distorted polar rays during
distorts shutdown.
1. Manufacturing quality of cathode ray is 1. Improve manufacturing quality of
not good, which causes dropping of cathode ray.
Cathode ray arista.
2. Regulate HV power supply control
arista drops 2. HV power supply control characteristic characteristics, reduce flashover, arc
or passivate is not regulated well; flashover, arc discharge in electric fields and replace
seriously discharging happens frequently in the burned cathode ray when it is
electric fields, which causes burning of necessary.
top end of arista of cathode ray.
1. Intension of bolts and jointing of fixing 1. Repairing welding should be done
Cathode cathode small frame is insufficient, which for the loosened frame, improve
small frame makes cathode small frame swing and jointing intension.
distorts and distort.
2. Stop boiler to correct distorted
swings 2. Cathode eccentric rapping is serious, cathode frame and repair the eccentric
which causes distortion of small frame. rapping fault.
1. Cathode rapping machine is in fault or 1. Deal with it as per method of
Cathode ray rapping force is small. cathode rapping machine fault;
accumulates hammer quality should be increased.
ash
2. Deal with it as per method of dealing
seriously 2. Cathode rapping control device is in
with cathode rapping control device
fault or its rapping cycle is too long.
fault; if rapping cycle is too long, stop
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time of rapping should be shortened.
3. Cathode ray is loosened, which 3. Improve installation quality and
causes serious attenuation of rapping repair loosened cathode ray.
acceleration.
4. HV power supplying equipments are
4. Oil film is adsorbed on cathode plate, not allowed to be put into operation
dust specific resistance is high with high when boiler burns fuel oil. Method of
viscidity, which makes it difficult to clean Intermittent Power Supply or Rapping
ash. when Electric Field Stops should be
adopted for high specific resistance
powder dust. Compressed air should
be used timely to clean accumulated
ash in electric field to ensure
cleanliness of plate surface.
4.4 Cathode and anode rapping device analysis and countermeasures
1. Jointing intension is insufficient, 1. Stop boiler to repair fallen hammer
Drop of welding of hammer and anvil surface and anvil surface to improve jointing
rapping drops under impact of rapping force. quality.
hammer or
impact 2. Hammer is small; shaft ruptures due 2. Stop boiler, repair or replace
bearing anvil to serious abrasion. abraded hammer shaft and shaft
sleeve.
1. Supporting points of rapping 1 Improve installation quality, regulate
hammers are not in a centerline, which coaxiality tolerance and bending
causes coaxiality tolerance and shaft degree to be within permit range.
bending degree exceed standard.
2. Bearing in dust is excessively
2 Replace abraded bearing with high
abraded, which makes shaft do down
quality bearing; enhance checking and
and lock.
maintaining bearing in dust.
3. Lengthways displacement due to hot
Rapping 3 Improve fixing intension of
expansion of rapping shaft exceeds
hammer, orientation bearing and leave sufficient
standard or orientation bearing
rapping shaft expansion clearance abundance to
displaces, which makes rapping
blocks or avoid collision of rapping hammer and
hammer and bearing bracket bump and
locks bearing bracket.
locks the shaft.
4 Improve installation quality and
4. Rapping hammer looseness, abrasion
jointing quality, enhance checking and
or displacement results in joggling of
maintaining, replace hammer and
hammer and anvil, which locks shaft.
anvil surface that can be easily locked.
5. Ash hopper is full with ash and
5 Deal with it as per method of dealing
rapping machine is buried in ash, which
with ash hopper block fault, rapping
causes rapping shaft blocking or locking.
should be stopped when as hopper is
full.
Rapping hammer, shaft is blocked and Deal with it as per method of dealing
Electric
overloading protector of rapping motor with rapping hammer and rapping
porcelain,
does not actuate effectively, which shaft blocking, improve sensitivity of
multi-direction
makes retorting torque exceeds rapping motor of overload protection,
joint or
mechanical intension of electromagnetic replace broken electric porcelain shaft,
security pin
shaft, multi-direction joint and security multi-direction joint or security pin.
rupture
pin and ruptures.
Speed 1. Speed reducer leaks oil or 1. Enhance periodic checking and

reducer or transmission part is abraded. maintaining of reducer, replace
258
drive abraded rubber sealing rings timely.
mechanism is Solid lubricating oil of molybdenum
in fault disulfide should be used to replace
2. Parts of drive mechanism are rusted liquid lube.
or impurities enter into moving parts that
2. Check and maintain periodically
make drive mechanism block.
during shutdown, fill oil and clean
impurities for drive mechanism timely.
4. Ash hopper fault analysis and countermeasures
1. Air lock is in fault, which causes ash 1. Deal with it as per method of dealing
blocking in ash hopper. with electric air lock fault.
2. Speed reducer, motor or transducer is 2. Repair or replace speed reducer,
in fault. motor and transducer.
3. Ash chute leaks air seriously, heat 3. Enhance ash chute sealing and
insulation performance is not good, which insulation.
makes ash chute block.
4. Ash hopper heating and insulation is
Ash hopper 4. Enhance heating for ash hopper
not good and leaks air seriously, which
blocking sealing and insulation. Installed wall
make ash wet, temperature decrease,
vibrator or gasification device on ash
fluidity worsen, which result in ash
hopper to avoid ash agglomeration.
agglomeration.
5. Stop boiler to check spoiler and
5. Ash hopper spoiler, especially its
stiffen its jointing.
moving part falls off easily, which makes
outlet of ash hopper block. 6. Smooth fluidizing air pipe, stop boiler
to check, and replace abraded fluidizing
6. Big ash hopper flume fluidizing air is
cloth.
not smooth, fluidizing cloth abases, ash
fluidity worsens.
4.6 HV insulation parts fault analysis and countermeasures
1. Electric heating device, electric heating 1. Repair heating device to keep
control equipment are in fault, which temperature in penthouse or beam
Dew makes temperature in penthouse or being always higher than dewing
formation beam too low and inner & outer temperature.
and temperature difference of insulator big,
creepage which causes dew formation and
at HV creepage. 2. Regulate purge holes clearances
insulation and block air leaking apertures by
2. Penthouse or beam leaks air, which
part welding.
causes excessive cold air intrude that
leads dew formation and creepage of HV
insulation part.
1. Insulator inner wall in polluted by oil 1. Purge and wipe accumulated ash
and accumulated ash; creepage or and dirty on inner and outer surfaces,
Flashover flashover may occur when insulator or keep surfaces of insulation parts clean.
and surface of insulation stick is wet.
2. Regulate HV power supply control
discharge
2. HV power supplying control characteristics to avoid frequent
at HV
characteristic is not good, operation flashover and arc discharge in electric
insulation
over-voltage due to high frequency fields, improve ability of resisting over
part
resonance over-voltage and intermittent voltage impact of HV power supply
arc occurs frequently in HV power supply equipments.
loop, which cause part shock of HV
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insulation part and flashover discharge.
1. Insulation parts produce sparkle and 1. Enhance checking and maintaining
discharges under effect of dew formation, of insulation parts to avoid dew
ash accumulation and oil pollution. formation, ash accumulation and oil
pollution on insulation parts surface.
HV 2. Supporting insulator and insulation
Replace the broken insulation parts
insulation stick rupture under frequent impact of
timely.
part rapping force.
damages 2. Replace with high quality supporting
insulators and insulation stick. Add
vibration decreasing measures to
reduce impact of rapping machine
toward insulation parts.
5. Preparation before Maintenance and Safety Measures & Notes during Maintenance
5.1 Preparation before maintenance
5.1.1 Prepare maintenance plan
Check operation parameters (secondary voltage, secondary current, running rate, running
hours etc.) of all electric fields of ESP before it stops, equipment defects, previous major & minor
overhaul conclusion and inspection records (measures of technical improvements, replacement of
spare parts etc.) from major and minor overhaul. Prepare major & minor overhaul plan through
analyzing all kinds of files, it mainly includes:
5.1.1.1 Prepare scheme, process flow, working personnel organizing plan and cooperation
between types of work.
5.1.1.2 Prepare detailed rules of technical measures and safety measures of important projects.
5.1.1.3 Plan must be approved by superior administrative department; important safety measures
should be examined and approved by safety supervision department.
5.1.2 Material preparation and ground arrangement
5.1.2.1 Material preparation includes preparations of material, spare parts, safety tools,
instrumental tools and meters and lighting tools.
5.1.2.2 Maintenance ground arrangement includes cleaning ground, division of working area and
material stacking area and management measures of spare parts at site.
5.1.2.3 Safety tools should be checked by special safety personnel, 12V portable light should be
used for lighting inside electric fields, creepage protector should be equipped when using 220V
lighting or maintenance power supply, breaker should be set at striking place outside manhole and
special personnel should be sent for supervision.
5.1.3 Prepare related technical record tables
Pole distance measuring record table, electric field empty load voltage rise test record table,
air flow distribution test record table, rapping acceleration measuring table and air leakage rate
measuring record table.
5.2 Safety measures and notes during maintenance
5.2.1 Work permit ticket must be strictly issued according to relevant safety regulations, complete
all safety measures; working personnel can only enter into site after approved by work approver or
maintenance principal to start work.
5.2.2 High altitude work inside and outside ESP should be executed according to relevant
regulations.
5.2.3 Inside maintenance of ESP can only be done after boiler stops, ESP outlet temperature
decreases to be lower than 50 by natural cooling and residual gas inside has been completely
removed. Fine ventilation should be kept during inside maintenance of ESP.
260
5.2.4 HV isolation switch must be switched to earth position before entering into ESP electric field
for work, using earth wire to discharge to output of silicon rectifying transformer; earth measures
should be done for dust collection pole of every power supplying area to avoid residual static in
electric fields. Additional earth wire must be set temporarily to avoid accident, that is make
discharge pole system and dust collection system earth with metal material (section area should
be bigger than 10mm2) at striking place. One earth wire should be set for each power supplying
area. It should be noted that it should be dismantled after maintenance.
5.2.5 All heating systems of ESP should be disconnected before entering into field of ESP for
maintenance, stop all the running equipments and cut the power; power send and cut rules should
be strictly executed during maintenance.
5.2.6 Warn plate of Working inside Field should be hung at striking place on control panel before
entering into fields inside ESP for maintenance.
5.2.7 All the ash hoppers should be free from ash in all fields before entering into fields inside ESP
for maintenance.
5.2.8 At least two working personnel should go inside field of ESP for work, one is for supervision,
and another person should be arranged outside manhole of ESP.
5.2.9 Lighting voltage for maintenance should no higher than 12V, there should be no creepage or
discharge at welding line.
5.2.10 After maintenance inside ESP is completed, clean the impurities and temporarily welding
parts; no acute angle, burr or tool is left inside ESP.
6. Maintenance Cycle and Items
6.1 Daily maintenance items
6.1.1 All moving parts should be checked and lubricated periodically.
6.1.2 Periodically check whether drive mechanism is running nor or not.
6.1.3 Check whether connection bolts and anchor are loosened or not.
6.1.4 Check sealing conditions of manholes and flanges.
6.1.5 Check whether accumulated ash in ash hopper has agglomeration and overloading or not.
6.1.6 Clean the defects that can be cleaned when boiler is running.
6.2 Minor overhaul cycle and maintenance
6.2.1 Its minor overhaul should be done together with the unit; its cycle is 6-12 months generally.
6.2.2 Minor overhauls items:
6.2.2.1 Clean the defects that can not be cleaned during operation, especially the fault inside
electric fields.
6.2.2.2 Clean or replace broken cathode ray and clean fault of short circuit. Check accumulated
ash and distortion at dust collection pole and discharge pole.
6.2.2.3 Check and regulate poles space should be within regulated range.
6.2.2.4 Check abrasion of bearing seat, wear resistant sleeve and hammer of anode & cathode
rapping system, welding line should be free from crack. It should be cleaned when any abnormity
is found.
6.2.2.5 Check whether cathode and anode rapping shaft (stem) have rupture and block or not;
clean it if any problem is found.
6.2.2.6 Check whether air flow distributing plate, groove plate and rapping system have defects or
not, replace seriously abraded distribution plates.
6.2.2.7 Check whether rapping, ash discharging drive mechanism is working normally or not.
6.2.2.8 Check whether positioning plate at lower part of anode plate has displacement and
261
distortion or not; clean it if there is any defect.
6.2.2.9 Clean accumulated ash and air leakage at inlet & outlet of gas duct, gas box, shell and
dead corner; repairing welding should be done for serious abraded flow guide plate and stiffening
plate.
6.2.2.10 Check fixing condition of ash hopper spoiler, it should be reinforced if necessary.
6.2.2.11 Check fluidizing groove and fluidizing cloth under big ash hopper, it should be replaced if
any is damaged.
6.3 Major overhaul cycle and item
6.3.1 Minor overhaul should be done together with the unit, its cycle is 4 years generally
6.3.2 Major overhauls main items:
6.3.2.1 Check ash accumulation at discharge pole and dust collection pole, clean the accumulated
ash.
6.3.2.2 Check positioning device of dust collection pole plate, replace the damaged pole plate and
pole ray.
6.3.2.3 Check and regulate poles space completely; check, correct and repair big frame of
cathode; check and correct small frame of cathode; check and correct cathode and anode pole
plate.
6.3.2.4 Repair rapping system and drive mechanism of discharge pole, dust collection pole,
distribution plate and groove plate.
6.3.2.5 Clean accumulated ash in ash hopper, penthouse, beam, insulator and insulation stick.
6.3.2.6 Check whether air flow distribution plate, groove plate system have defect or not, replace
the seriously abraded distribution plate.
6.3.2.7 Dismantle and repair electric air lock.
6.3.2.8 Clean accumulated ash and air leakage at inlet & outlet of gas duct, gas box, shell and
dead corner; repairing welding should be done for serious abraded flow guide plate and stiffening
plate.
6.3.2.9 Check fixing condition of ash hopper spoiler, it should be reinforced if necessary.
6.3.2.10 Check fluidizing groove and fluidizing cloth under big ash hopper, it should be replaced if
any is damaged.
6.3.2.11 Replace all sealing stuffing material of manholes.
7. Maintenance Process and Quality Standard
7.1 Ash cleaning process, method and notes inside electric field
Ash
cleaning Process method Note
process
1. Cool down the electric field wholly and naturally Sudden cold air entering
for 12h, and then open the manholes for should be strictly prohibited,
accelerating cooling. which may result in distortion
1. Cooling of metal components such as
electric field 2. When temperature inside electric field
shell, pole line and pole plate
decreases to 50, working personnel can enter etc.
into it for work.
2. Check 1. Check ash accumulation of anode and cathode Lighting facilities should be set
before plate, analyze the reason and make records well. before entering into electric
cleaning ash 2. Check electric ash accumulation on field inner field. Personal safety and
top, side wall, air flow distribution plate, groove protection measures should
262
plate, flow guide plate and air baffle, analyze the be done well. At least two
reason and make records well. working personnel should
enter into electric field for work
3. Check ash accumulation at ash hopper inner
and at least one personnel
wall, bottom and spoiler; analyze the reasons and
supervise outside.
make records well.
4. Check poles distance, pole plate bending
excursion, cathode frame distortion, pole ray drop
or loosening; make records well.
1. Clean accumulated ash inside field including No tools for cleaning ash may
cathode ray, anode plate, rapping device, groove left or dropped into ash
plate, inlet & outlet gas box, flow guide plate, air hopper.
distribution plate, shell inner wall and grinder etc.
3. Clean 2. When ash is blocked in ash hopper, generally it
accumulated is not allowed to discharge from manhole.
ash inside Pneumatic transportation system should be
electric field adopted to remove accumulated ash in ash
hopper.
3. Ash cleaning should be done from above to
below, from inlet to outlet, both compressed air
and water can be used to purge or flush.
7.2 Maintenance content, process method, notes and quality standard of anode system
Content Process method and notices Quality standard
1. Check bending condition of anode plate with Plane error 5mm and
eyeballing or drawing line. catercorner error 10mm.
1. Check
2. Check rust and electric corrosion of polar
completeness
plate, find out the reason and eliminate it.
of anode
plate 3. Polar plate that polar distance can be ensured
due to too great damaged area should be
replaced.
1. Check whether joggling of anode plates is 1. Anode plates row
good or not, treat it if it is not good. combination is good and free
from coming away.
2.ESP1: Check fixing bolts of upper and lower
polliwog beam of anode plates row, replacement 2. Left and right moving
or welding should be done if necessary; anode clearance is about 4mm and
plate should be limited within limit plate with a can move slightly. Fixing bolts
certain moving clearance. are free from loosening,
falling off and missed spot
ESP2: Check fixing bolts of on suspending
welding.
2. Check plate and rapping plywood of anode plates row,
completeness replacement or welding should be done if 3. Hot expansion clearance
of anode necessary; rapping stem should be limited within should be calculated
plates row comb mouth of air baffle of ash hopper. according to polar plate height
and maximum temperature of
3. Check hot expansion clearance between
gas with one times
anode plate lower part and comb mouth of air
abundance and no less than
baffle of ash hopper, it is required that there
25mm. Both left and right side
should be sufficient hot expansion abundance
should be smooth and free
above and below, there is no block at left or tight.
from steps.
4. Check displacement in sinking direction and
4. Level degree tolerance is
air flow direction, compare it with rapping center.
5mm, catercorner error
If it sinks, check whether suspending beam is
L/1000 and maximum
bended and distorted or not. Regulate it if it is
263
bended or distorted. 10mm.
5. Combination of whole plates row should be
fine and there is no obvious protruding or
concave on polar plate by eyeballing.
3. Inspect Take straight anode plates row in middle of each Table records should be clear
homopolarity electric field as benchmark, measure and dates are true.
distance of homopolarity distance with polar distance plate.
polar plates Space should be measured at outlet of every
polar plates row; take three points of up, middle
and low along polar plate. It should be measured
at same positions during every minor and major
overhaul, record the measured values well.
4. Whole 1. Regulate the distorted polar plate if Permit error of homopolarity
regulation of homopolarity distance exceeds standard, distance of anode plate is:
polar plate regulation can be done by knocking maximum
When polar height 7m,
bending place with wooden hammer or rubber
7mm;
hammer, and then reduce force evenly to extend
to two ends. Knocking points should be at two When polar height 7m,
sides of polar plate, it is prohibited to knock on
10mm;
working surface. Fire baking can also be adopted
if it is necessary. All bolts tightening fittings of
anode plates are complete
2. When polar plates displace or sink,
and free from looseness.
homopolarity distance exceeds regulation and
can not be eliminated at site and whole row of
polar plates should be replaced, the top should
be taken off.
3. The new anode plates should be tested
according to manufacturers regulations, error of
back plane and catercorner of anode plates
combination complies with manufacturers
requirements, suspending should comply with
original arrangement type.
7.3 Maintenance content, process method, notes and quality standard of anode rapping device
Check ash accumulation on anode plate and find
1. Rapping
out electric fields and anode plates row with bad
effect
efficiency.
1. Check rapping center deflection of impact 1. Under working condition of
bearing anvil and abrasion of impact bearing rapping system, lower
anvil, check whether impact bearing anvil and contacting position of hammer
hammer are loosened, fallen and ruptured or not, and anvil should be in middle
whether bolts and jointing parts are fallen or not. from up to down and left to
2. Repair
Regulate it and reinforce it. right (error is 5mm), they do
and regulate
not contact slantways,
impact 2. Hammer position regulation should be done
contacting line of hammer and
bearing anvil after repayment of anode plates row and drive
anvil L should be longer than
and rapping mechanism. Height of bearing in dust should be
1/2 of total length during
hammer regulated when serious radial deflection occurs in
complete contact.
whole rapping system; height of motor and speed
reducer should also be changed if necessary. 2. Replace the abraded
Fixed position of bearing in dust and fixed hammer and anvil. Hammer
position of speed reducer of motor should be and arm turn freely and can
drop freely after turning to
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regulated if serious axial deflection exists. critical point. Fit clearance
between hammer small shaft
3. Check abrasion of sleeve of small shaft of
sleeve and outer sleeve is
hammer, it should be treated or replaced when
about 0.5mm.
abrasion is excessive and hammer can not drop
freely at critical point. Different degree of
repairmen or replacement should be done when
hammer and anvil joggle to avoid locking of
rapping shaft.
1. Check whether bearing seat (bracket) is 1. It should be replaced when
distorted or not, whether orientation bearing radial abrasion thickness of
displaces or not. Check abrasion parts such as bearing in dust exceeds 1/3
bearing, cast iron pieces of bearing in dust; it outer diameter of original
should be replaced if necessary. bearing, shaft and parts those
can not be used until next
2. Check rapping bearing: turn rapping system,
3. Repair overhaul should be replaced.
check whether all shafts bend, deflect or not; it
rapping should be regulated if exceed standard shaft flops 2. Tolerance of coaxiality
shaft, or is blocked. When shaft sinks, but bearing between two neighboring
bearing and abrasion, coaxiality tolerance and shaft bending bearing seats is 1mm,
bearing seat degree do not exceed standard values, it can be compensation pieces quantity
compensated by adding gasket under bearing should not exceeds 3 pieces
seat. Plane correction and alignment must be worm shaft total length is
done for the same running shaft and bearing 3mm.
seat. Rapping shaft centerline must be centerline
of al bearing seats, it should be regulated if it
exceeds standard.
1. Check whether coupling and connection bolts 1. Flange connection should
have looseness, dropping, breaking or not, it be fine and no bolt drops.
should be replaced if there is.
2. Multi-direction joint is free
2. Check and replace multi-direction joint with from mechanical damage.
crack or part rupture.
3. There is no block between
4. Repair
3. Check whether driven stem and copper shaft driven stem and copper shaft
rapping
sleeve are blocked or not, regulate or repair the sleeve.
connection
blocked part.
parts 3. Security piece (pin) is free
4. New rapping security piece (pin) should comply from damage.
with manufacturers regulations. Do not mix the
4. There is no air leakage at
security pieces of anode and cathode.
shaft-through part of rapping.
5. Replace the gland packing sealing at
through-wall places.
1. Check whether speed reducer leaks oil or not, 1. There is no block, flopping
whether seat is complete or not and has crack or or periodical noise during
not; whether oil pointer level indication is clear or turning gear.
not.
2. Temperature rise of speed
5. Repair
2. Start motor, check whether speed reducer has reducer 50
abnormal sound or vibration or not, whether
rapping
temperature rise is normal or not. 3. Needle teeth sleeve should
speed
be smooth and free from rust
reducer 3. Open oil filling hole at upper section of speed
spot, concave or protruding.
reducer, check abrasion of needle teeth sleeve in
speed reducer, replace the oil for speed reducer 4. Oil pointer indication is
with abnormity and block the oil leakages. clear.
4. Dismantle and repair the speed reducers, of
which sound is abnormal, vibration and
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temperature rise and running time exceed
regulations.
1. Dismantle connection of motor, clean shell Dismantling of speed reducer
platform, discharge oil and make serial numbers should be done in sequence of
for speed reducer. dismantling steps. Marks and
records should be done well.
2. Dismantle anchor bolts, lift them to designated
location and mark the junction surfaces of the
body.
3. Demount output coupling.
4. Demount connection bolts of input end cover,
take off input shaft of motor, bearing and
6. Dismantle eccentricity sleeve together.
and repair
5. Demount cycloid wheel A, ring spacer,
rapping
eccentric bearing and cycloid wheel B, pat
speed
attention position of A relative to B.
reducer
6. Dismantle connection bolts between needle
teeth gear, take off needle teeth shell, needle
teeth pin and cover.
7. Knock output shaft end with purple copper stick
along axial direction to separate shaft and seat.
8. Clean parts, measure dimension of all parts
and make technical records well.
9. Replace easily damageable parts such as
bearing, ring spacer and oil sealing.
1 A and B of two cycloid wheels must be in Reinstalling of speed reducer
superposition, and character head should point should be done in opposite
upwards. sequence of above
dismantling steps.
2. Shaft pin insert into corresponding hole, pay
attention to the position of ring spacer, fix it with
pin shaft sleeve to avoid damaging ring spacer.
7. 3. Spread grease on rolling and sliding surface.
Reassemble 4. Heating installation can be adopted for shaft
rapping installation.
speed
reducer 5. Sealing gaskets should be replaced.
6. Clearances of all parts reach to regulated
values.
7. Reinstalling is completed, turn the motor air fan
manually check it rotating condition.
8. Fill oil before trial run, oil level should be strictly
controlled at centerline of oil pointer.
1. Reset rapping hammer. It can be turned manually,
running direction is right,
2. Turn turning gear manually and check running
8. Trial run motor is not overloaded,
and rapping points.
after security pipe (pin) ruptures,
maintenance 3. Test motor running direction before reinstalling shaft blocks; speed reducer
security piece (pin). sound and temperature rise
are normal.
4. The whole rapping device should be in trial run
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for 1h before reinstalling security piece (in).
7.4 Maintenance content, process method, notes and quality standard of cathode system
1. Check 1. Wipe supporting insulator, insulation stick 1. Supporting insulator and
and repair surface with clean, dry and soft cloth; check insulation sleeve are free from
cathode whether insulation part surface has mechanical mechanical operation and
suspension damage, insulation damage and discharge trace insulation damage.
device or not; replace cracked supporting insulator and
2. Test standard of HV
insulation stick. Corresponding fastness measures
insulation part is 1.5 electric
must be done to replace supporting insulation
field rated voltage and AC
parts, move supporting points to temporary
voltage, it should not be
supporting points. It should be ensured that four
shocked through within 1min.
supporting points are bearing force evenly to avoid
damaging other three supporting points. 3. Concentricity error of
dustproof sleeve and
2. Voltage resistant test should be done before
suspender <5mm.
replacing insulation parts, stuff bottom of insulator
with asbestos rope after replacing insulator to
avoid air leakage.
3. Check whether nuts at top of big frame
suspender are loosened or not, whether position
relative to other fastness part of big frame has
changed or not; regulate properly according to
actual conditions. Check big frame level degree
and vertical degree; take records for the
convenience of analysis.
4. Check that concentricity of dustproof sleeve and
suspender is within permit range, otherwise
dustproof position should be regulated properly.
2. Repair 1. Detect whether tolerance of cathode big frame 1. Level degree tolerance
cathode level degree complies with requirement or not and <20mm.
big frame align it.
2. Catercorner tolerance of
2. Check part distortion, welding dropping and cathode big frame is 10mm;
crack of big frame; regulate and reinforce it. the structure of whole big
frame is firm and free from
3. Check whether ladder on big frame is loosened
crack, dropping or distortion.
or not, reinforce it.
3. Repair 1. Check fastness condition of small frame and big 1. All small frame should be
cathode frame; correction and repairing welding should be free from distortion or
small done if distortion, twisting or abrasion is found. looseness and well fixed on big
frame frame.
2. Check and correct vertical degree of small
frame, it should be corrected if it exceeds 2. Tolerance of vertical degree
regulation. of small frame is 5mm.
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4. Repair 1. Check fastness of cathode ray, find out fault Cathode ray is free from
cathode reason and treat with it. Check the loosened polar looseness or broken line. Polar
ray ray, the fault reason should be found and tightness distance in electric field can be
should be done if any abnormity is found. ensured and discharge
performance of cathode ray is
2. Check performances of different types of
fine.
cathode rays and take records for completely
analyzing running condition. Except for checking
looseness, broken line and ash accumulation,
following items also should be checked for
cathode ray:
Arista: discharging pole passivate, regulation of
distance between two top end.
Fishbone needle: needle looseness condition and
needle end passivation condition.
3. Replace with same type and specification
cathode ray, detect whether cathode ray is fine or
not before replacing, bended parts should be
corrected to make it comply with manufacturers
regulated requirements.
4. Special frame should be added when regulating
or replacing small frames with great distortion or
many faults to make frame be vertical during polar
line replacement. Relative position of suspended
frame and cathode rapping shaft should keep the
same.
5. Inspect 1. Different polar distance should be detected after 1. Data is recorded clearly,
and maintenance of big and small frame and measurement has been done
regulate homopolarity distance is regulated to be within carefully and rightly.
polar normal range. For the different polar distance that
2. Permit error of different polar
distance has been reaches after regulation, its regulation
distance: 10mm. All different
should be marked and data before and after
polar distance should comply
regulation should be recorded in equipment files.
with standard.
2. For the convenience of work, measuring points
are generally arranged on the first polar line at
inlet and outlet side of every electric field.
3. Make measuring table according to detection
points arrangement, recoding content should
include: Electric filed name, channels quantity,
detection points numbers, cathode ray number,
measuring personnel, measuring time and
measured data. Measuring detection points should
keep the same as much as possible during every
major overhaul. Compare the detection points
during installation and major overhaul for analysis.
4. Detect and current homopolarity, big & small
frame and polar line according to standard
requirements to ensure all detection points of
different polar distance be within standard.
Distance of other parts between anode and
cathode are measured by eyeballing or special T
type limit gauge.
7.5 Maintenance content, process method, notes and quality standard of cathode rapping device
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1. Combined with ash accumulation of cathode Refer to anode rapping
ray, find out the electric field and cathode ray with standard, select center error,
insufficient rapping force. contacting length and
abrasion depth according to
2. Check center deflection of hammer and impact
proportion of cathode rapping
bearing anvil under working condition, specific
and anvil.
maintenance method is same with that of anode
rapping.
3. Check bearing in dust and rapping shaft, the
1. Check method is same with that of anode rapping.
and treat 4. Repair rapping connection parts, the method is
cathode same with that of anode rapping.
rapping
system 5. Method for maintenance of rapping speed
reducer is same with that of anode rapping. Check
abrasion of idler pulley and cam of lifting device, it
should be replace if abrasion is serious, spread
grease after installation. It should be replaced if
spring ruptures during reset.
6. Check whether connection pin between lifting
stem and insulation stick ruptures or not, find out
the reason and eliminate it, replace connection
pin.
Clean the accumulated ash on insulation stick with 1. Insulation stick should be
soft cloth; check whether there is crack or free from mechanical
2. discharge trace, insulation stick with crack, rupture damage and insulation
Maintenance or discharge trace should be replaced. Voltage damage.
of cathode withstand test should be done before replacement.
rapping 2. Test standard of insulation
insulation stick: 1.5 electric field rated
stick voltage and AC withstand
voltage, it should not be
shocked thoroughly in 1min.
7.6 Maintenance content, process method, notes and quality standard of ash hopper and ash
discharging device
1. Check corrosion on inner wall of ash hopper, 1. Ash hopper inner wall is
check flange junction surface, welding line crack free from leaking point and
and air hole leakage combined with checking scar.
ash leakage and corrosion when equipments are
2. Four corners of ash hopper
running. Scar must be grinded by grinding
are smooth and free from
machine after repairing welding to avoid ash
dead comer.
accumulation.
3. Ash hopper is free from
1. Ash hopper 2. Check arc plate on ash hopper corner is
distortion and supporting
maintenance complete or not, it must be smooth and free from
structure is in fastness.
scar after repairing welding to avoid ash
accumulation. 4. Spoiler does not drop or
incline.
3. Check abrasion and fastness of supporters in
ash hopper and suspending grinder of spoiler in
ash hopper; reset or repairing welding should be
done timely if abrasion or displacement is found.
4. Check abrasion and distortion condition of
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spoiler in ash hopper, check abrasion of ear
plate and flying rings of moving parts of spoiler;
repairing welding or replacement should be
done.
Replace sealing stuffing material at ash hopper Flashboard valve has no
flanges and flashboard valve; eliminate ash leakage and can be operated
2. Flashboard
leaking points of all parts. Check whether reliably. It is isolation
valve
actuator of flashboard valve turns freely or not, performance is good.
maintenance
regulate it, remove rust and fill oil for
maintaining.
3. Ash chute Check and deal with ash accumulation in ash Ash chute is smooth and free
maintenance chute. from leaking points.
1. Check whether shell of ash discharging valve 1. Clearance between
has crack, dilapidation or not. impeller and shell 1mm
2. Dismantle wheel-set pin of speed reducer
2. Bearing is free from
motor, dismantle anchor bolts of speed reducer
exuviations, overheating,
and move it. Dismantle the transmission part
color changing or crack.
(chain wheel, chain) of output shaft of speed
reducer. 3. Bearing housing is strict
and free from leakage.
3. Dismantle bearing bracket, bearing; check all
parts clearance and replace it if clearance is not 4. Speed reducer gear can be
qualified. turned freely.
4. Check clearance between impeller and shell 5. Joggling of chain wheel
4. Ash and abrasion of all parts before dismantling ash and chain is good.
discharging discharging valve, rear end cover and drawing
valve 6. Connection of bolts are
out rotor (impeller). It should be replaced if
dismantle and tight and reliable.
impeller abrasion is serious or impeller has
repair indentation.
5. Dismantle front and rear bearing and bearing
cover, clean then with industrial detergent, check
bearing abrasion. Replace it if it is seriously
abraded.
6. Check and replace chain wheel, chain wheel
key and chain.
7. Dismantle and check speed reducer, replace
lubricating oil.
8. Method of maintenance of speed reducer is
same with that of anode rapping reducer.
Sequence of reassembling of ash discharging Reference dimension of
valve is opposite to that of dismantling, following radial clearance is: 0.7
points should be noted:
1.5mm.
1. Radial fit between impeller and shell, measure
5. Reference dimension of axial
the clearance around with feeler gauge and
Reassembling regulate them to be even. clearance is: 1.54mm.
of ash
discharging 2. Regulate clearances between front and rear
valve end cover, impeller and shaft.
3. A layer of lubricant should be plastered before
filling new stuffing material; space should be left
after tightening stuffing material. Pressing cover
does not incline.
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4. Before installation of bearing, grease should
be plastered on rolling surface. Holes on bearing
should aim at holes on end cover and no air
interfusion is allowed.
1. Turn the assembled coupling of ash After 1h trial run, rotor turns
6. Assembling
discharging valve. freely and is free from friction
and trial run of
or axial movement, center
ash 2. Take coupling of ash discharging valve as
error <0.05, no ash leakage.
discharging benchmark, align speed reducer.
machine
3. Connect power supply, trial run for 1h.
7.7 Maintenance content, process method, notes and quality standard for parts of shell, inlet &
outlet gas box and manhole
Content Process method and note Quality standard
Check corrosion of shell inner wall, repairing Shell inner wall should be free
welding should be done for parts with water from leakage, corrosion and
leakage and air leakage; kerosene penetration inner wall should be straight.
1. Shell inner method should be adopted to watch leakage if
wall necessary. Check powder dust accumulation of
inner wall, the reason should be found out and it
should be corrected if there is distortion on inner
wall to avoid vortex.
Check sealing of ash hopper manhole, electric Manhole has no leakage,
field maintenance manhole, and top beam safety signs are complete and
manhole and penthouse manhole. Replace it can be opened and started
2. Manhole sealing stuffing material if it is necessary, correct conveniently.
the distorted manholes and replace damaged
bolts. Signs of High Voltage, Danger! should be
complete and clear on manhole.
Check that ESP shell insulation layer and guard Insulation thickness is
plates should be smooth and fine, repair the 100-200mm, insulation layer
3. Shell parts with dilapidation, rust concave or should be filled tightly,
insulation protruding. thickness is even, which meets
insulation requirement, metal
guard plates are complete.
1. Check and record abrasion condition of inlet & 1. Inlet & outlet gas boxes
outlet gas box and supporting fittings; regulate should be free from distortion,
flow guide plate in gas duct if necessary; add leakage or excessive abrasion
wear resistant liner at parts seriously abraded.
2. It should be replaced wholly
Repairing welding should be done for parts with
when abrasion area of
water leakage and air leakage. The seriously
distribution plate exceeds
abraded parts should be replaced.
30%.
2. Check whether junction surfaces of inlet &
4. Inlet & 3. Equality standard of air flow
outlet gas boxes and gas duct flanges is fine or
outlet gas not, repair and reinforce concave on inner wall. at inlet section of field one
box
3. Check abrasion and jointing fastness of flow 0.25.
guide plate, air flow distribution plates and
groove plates, replace the damaged fastness
parts and bolts.
4. Check abrasion of flow guide plate,
replacement or repairing welding should be
done.
5. Check abrasion and level degree of
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distribution plate, mend the distribution plate
with big holes according to original distribution,
seriously abraded plates should be replaced.
Distance between bottom of distribution plate
and inner wall of inlet gas box should comply
with design requirement. Distribution equality
test should be done after maintenance of air flow
distribution plates and flow guide plates for the
ESP, dust handling efficiency of which can not
reach design requirement. Regulate flow guide
plate angle, openings of air flow distribution
plate according to test results until they comply
with requirements.
6. Maintenance for rapping device of distribution
plates should be done as per anode rapping.
7. Check abrasion and distortion of groove plate,
relevant repairing welding, correction and
replacement should be done.
5. Stairs, Check rust corrosion and dilapidation of stairs, Stairs, platform, guardrail and
platform, platform, and guardrail and rainproof shed; rainproof shed are complete
guardrail and repayment and rustproof maintaining should be and firm.
rainproof done.
shed
Chapter Pipeline System and Valve Maintenance
1. Applicable range:
This regulation is applicable for ash handling pipelines and valves overhaul and maintaining of
Indonesia Paiton 1660MW coal fired thermal power plant.
2. Quoted standard
DL-T748.92001 Guide of maintenance of boiler unit for thermal power station Part Three:
Valve and Steam Water System Overhaul
JB/T 53001991 General-purpose valve Material
GB/T 122361989 General-purpose valve Steeliness swing check valve
GB/T 122371989 General-purpose valve Flanged and butt-weld end steel ball valves
GB/T 122381989 General-purpose valve Flange and wafer connection butterfly valve
GB/T 122411989 General requirements for safety valve
GB/T 122431989 Spring direct loading type safety valve
GB/T 139271992 General-purpose valve Pressure Test
JB/T 90921999 Valve inspection and testing
3. Pipeline System Maintenance
3.1 Summary
Pipeline adopted by ash handling system is middle pressure and low pressure one; it can be
divided into carbon steel pipe, stainless pipe and rubber flange tube according to different
272
materials.
3.1.1 Application scope for pipelines
3.1.1.1 Carbon steel pipes are usually used on air transportation and water system pipelines.
3.1.1.2 Stainless pipes are mainly used on pipelines of nozzle purging, pneumatic valve control
and sampling system.
3.1.1.3 Rubber flange tube is mainly used at interface of returned and supplying water of spraying
water gun and ends of fluidizing air branch pipe of ash hopper and circulation flume.
3.2 Pipeline maintenance process and requirement
3.2.1 Preparation.
3.2.1.1 Get familiar of installation drawings of pipeline and related requirements.
3.2.1.2 Learn and set down technical measures for organization and construction.
3.2.1.3 Check that all tools and machines are complete and qualified.
3.2.1.4 Check preparation of pipeline and its accessories. Check pipe surfaces quality, whether it
has crack, hollow, folds, double-skin and slag inclusion or not.
3.3 Pipeline process
3.3.1 Pipe incision
Generally mechanical method or air cutting method is adopted for cutting middle, low
pressure carbon steel pipe and stainless pipe. Nozzles after cutting should be grinded to be a V
type sloping gap by special grinding machine. Requirement: Cut should be neat and free from
crack, double skin, burr, concave and protruding, sinter or ferric oxide scale; cut plane incline
difference is 1% of pipe diameter but should not exceed 3mm.
3.3.2 Bending for small diameter pipe
3.3.2.1 Hydraulic pressure pipe bender is generally adopted for steel pipe with diameter less than
DN25 for cold state process, minimum bending diameter is 4 times of pipe diameter.
3.3.2.2 Heat-bending treatment is generally adopted for steel pipe with diameter less than DN50
for process. Specific method is as following:
Block one end of the pipe with stopper and fill in qualified sands from the other end; sand
filling should be done in sections, knock the pipe with hammer after filling a section that is about
300mm400mm. Sand particles should be considered according to pipe diameter; 13mm sand
may be used for pipes with outer diameter of no more than 65mm. Sand is heated up to 300 for
standby. Reinforcing steel bar with length of 10-15mm should be bended to required shape as per
requirement as templet. Draw lines on pipe and heat up the part required to be bended with fire
welding. During heating up, turn flame or pipe regularly to make heating even, heating
temperature of carbon steel should be controlled around 1000, under which pipe shows saffron;
for pipe with diameter less than 32mm or bending degree is not big, the heating temperature can
be slightly lower. Before bending, two ends of pipe to be heated should be cooled down with water.
The part that can not be easily bended due to stiffening by quenching should leave space for
bending, fixed the part that not be bended, and then bending syphon can be started; when syphon
is almost the same with the templet, templet should be put on it for bending to avoid losing shape.
When the temperature of pipe decreases to 700 (dark cherry), bending should be stopped,
reheat it and then bend it; but heating times should not exceed two times. Because syphon may
extend back after cooling, the bending angle should be 2o3o bigger than required one. After the
bended syphon is qualified by checking with templet, cool down pipe and spill sand, spread
machinery oil on heating surface to avoid repeated rust by oxidation.
3.3.2.3 Technical requirements for bending pipe
273
The appearance of bended pipe should be free from crack, delamination and over burning, the
reduced thickness of middle pressure and low pressure pipe wall should not exceed 15%, ellipse
degree should not exceed 8% and bending degree complies with requirement.
3.3.3 Screw machining of pipeline, if the quantity of required screw for machining is great, it should
be done at site, methods is as following:
Fix the pipe to be machined on pipe vice and the end that needs screw machining should
extent 150mm out, low down the reamer device, level and fix the scale pan and put the pipe at
corresponding scale, tighten the fixing handle of scale pan, and then push sleeve into pipe to
make their teeth in level, tighten it but not too much, working personnel stand in front of pipe end
with one hand holding reamer and pushing forward and the other hand turning handle, when teeth
enter into pipe for two rings, add machinery oil on it, cool and lubricate teeth, continue to turn
handle evenly to make teeth move forwards slowly. Screw is generally machined to be taper to
make connection tight.
To save labor and avoid excessive abrasion, pipe with diameter less than 40mm should be
machined by twice machining and pipes with diameter of 50mm and more should be machined for
several times.
3.3.3.1 Technical requirements for screw machining of pipeline: screw of pipes should be clear,
complete, smooth and free from burr or floss; total length of screw breaking and lacking should not
exceed 10% of screw thread length, there should be no broken thread in length.
3.4 Pipeline jointing
3.4.1 Before jointing, sloping gap must be processed for pipe; processing method of sloping gap
can adopt pipe beveling machine, fire welding cutting, electric grinding and machining by machine
tool. Blunted edge with 1-3mm should be processed and the sloping gap should be smooth with
metal gloss. Inner and outer side within 15-20mm of pipe wall should be clean and free from
impurities.
3.4.2 Align the centerline of jointing pipe before jointing, regulate interface clearance 0.53mm.
Pipe mouth section should be in vertical with pipe centerline with windage of no more than 1%.
When pipe diameter is smaller then 100mm, the windage should not exceed 2mm.
3.4.3 After pipe alignment, fix it with spot welding, weld 2-4 point along circumference, length of
spot welding is 2-3 times of pipe thickness, width should not exceed 70% of pipe thickness.
3.4.4 Pipes with spot welding should not be moved randomly, welding line should be shoveled and
spot welding should be done again if crack occurs at spot welding places, welding line height
should be 13mm higher than sloping gap.
3.4.5 12 welding lines should be welded at pipe end of inner side of flange during jointing of
flange and pipe.
3.4.6 Pipes should be filled up firmly before jointing, rolling welding should be adopted by all rolling
pipes.
3.4.7 Technical requirement of pipeline jointing
3.4.7.1 Distance from welding line to edge of supporting frame should be no less then 50mm,
distance between neighboring welding lines should be no less than 150mm and no less than outer
diameter of pipe.
3.4.7.2 All welding lines should be free from crack, air hole, slag inclusion and hollow; welding line
dimension should comply with regulation and its error does not exceed 2mm.
3.4.7.3 When jointing flange and pipe, pipe should be inserted into flange, a certain distance
should be left from sealing surface, the inserted depth of pipe is generally 1/2-1/3 of flange
thickness, vertical error of centerline of flange end surface and pipe centerline should be less than
2mm.
3.5 Flanges connection of pipeline
274
3.5.1 Before installation of flanges, check that sealing surfaces of flanges and sealing gaskets
should be free from sand hole, crack, radial groove and burr, which influence sealing performance.
3.5.2 Clean pipe ends to be connected, clean impurities on sealing surface and check pipe
inserted depth.
3.5.3 Flanges should keep parallel and its error should not be bigger than 1.5/1000 of flange outer
diameter and should not exceed 2mm.
3.5.4 Flange plane and pipe axle should be in vertical, impurities should be cleaned after welding.
3.5.5 Inner diameter of gasket for flanges should be 2-3mm bigger than inner diameter of flange, it
should be cut into whole round.
3.5.6 Two sides should be plastered with black ceruse evenly when installing sealing gasket for
the convenience of dismantling in following maintenance. Rubber gasket is prohibited on air
pipeline.
3.5.7 Except for special conditions, bolts with same specification should be used for flange
connection and their installation direction should be same. Bolts should be symmetrically tightened
with proper tension; black ceruse should be plastered on volts before installation of bolts to avoid
biting screw threads.
3.6 Check, regulate and repair supporting frame of pipeline
3.6.1 Check whether connection parts of bolts are loosened or not.
3.6.2 Check whether welding line is free from crack or not.
3.6.3 Check whether pipe clamp, pipe clip and sleeve are loosened, inclined or not.
3.6.4 Check that suspending stem, connection nuts of flange bolts are bended and damaged or
not.
3.6.5 Check that guide supporting seat and moving supporting seat should be free from blocking,
moving pieces should be free from rupture.
3.6.6 Check that bottom buried pieces are not loosened.
3.6.7 Repair, weld or replace according to actual conditions.
3.6.8 Technical requirements of installation of supporting frames
3.6.8.1 When installing supporting frame on concrete pole or beam, rendering coat of concrete
should be chiseled and then fix it.
3.6.8.2 Fixing bracket on pipeline should be installed according to design drawings. Two or more
fixing brackets can not be installed on straight pipe section of hot pipeline without compensation
device.
3.6.8.3 Bracket can be shared by several parallel pipelines during laying, but suspender of
supporting frame should not installed on any two pipelines with opposite displacement direction or
unequal displacement.
3.6.8.4 Expansion bolts must be divided into an enough depth when fixing supporting frame on
concrete foundation with expansion bolts.
3.6.8.5 Sliding surface of guide bracket and sliding bracket should be clean and smooth; moving
parts should contact with supporting pieces well to ensure free expansion of pipeline.
3.6.8.6 All moving parts of moving bracket should be naked and not cover by concrete or insulation
layer.
3.6.8.7 Fixing and regulation should be done timely during pipeline installation. Supporting frame
position should be right.
3.6.8.8 For pipeline with hot displacement, it should be checked and regulated as following when
in hot expansion:
1) Displacement direction, displacement amount and guide performance of moving bracket
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should comply with design requirements.
2) Pipe holder should be free from falling off.
3) Fixing supporting frame should be reliable.
4) Spring supporting bracket installation height and spring working height should comply with
design requirement.
3.6.8.9 After regulation of supporting frame, all lock nuts should be locked tightly to avoid
looseness.
3.6.8.10 Bolts holes of suspending frame and holes of fixing seat should comply with design
requirement.
4. Valve Maintenance
Valve is a control device of pipeline, its basic function is to connect or cut medium in pipeline,
to change medium flow, to regulate medium pressure and flow to protect pipeline for normal
operation.
4.1 Spring safety valve maintenance
Spring safety valve is an automatic valve, it can discharge a certain amount of liquid not by any
outside force to avoid pressure in system exceeding preset safety value. When pressure recovers
to be normal, it can close automatically to stop medium flowing out continuously.
4.1.1 Basic requirements of safety valve
Safety valve must be with two requirements of economy and safety. During its action, it must be
with: sensitive start, sufficient discharge, timely resetting and reliable sealing.
4.1.2 Action principle of safety valve
In spring safety valve, spring pretension force of spring effecting downwards on valve clack,
part of which is for resisting medium force and the other part is for compaction stress between
sealing pieces; with the increase of medium pressure, tensioning force between sealing fittings
reduces correspondingly. When medium pressure increases to rated startup pressure, the mutual
tensioning force is zero, safety valve opens for discharging; it reset automatically after pressure
recovers.
4.1.3 Structural sketch map of spring safety valve
1 Valve body
2 Valve seat
3 Regulation ring
4 Valve clack
5 Guide sleeve
6 Valve cover
7 Spring
8 Valve stem
9 Spanner
10 Regulation nuts
11 Protection cover
4.1.4 Maintenance items

4.1.4.1 Check and clean valve body and cover.
4.1.4.2. Check and clean valve element, seat and stem.
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4.1.4.3. Check and clean spring, spring seat, backwash plate and guide sleeve.
4.1.4.4. Check, clean and grind all sealing surfaces and tightening pieces.
4.1.4.5 Safety valve setting and adjusting
4.2 Gate valve maintenance
Gate valve is a closing piece (gate plate) that moves along vertical line of access centerline.
It is mainly for cutting in pipeline; gate valve with diameter less than DN15mm is not allowed for
throttle.
4.2.1 Advantages and disadvantages of gate valve
Gate has a sound sealing performance and low flowing resistance, it is easy to open and
close and medium flow direction is not limited. Erosion to sealing surface by working medium is
smaller than stop valve. Its structure is simple and casting performance is good. Its needs big
space and ling time to open; sealing surface is easily eroded and scraped during opening and
closing. Gate valve has two sealing surfaces generally, which brings difficulty for processing,
grinding and maintaining.
4.2.2 Gate valve sort
4.2.2.1 Gate vales can be divided into parallel gate valve and wedge gate valve according to
structures.
a. Parallel gate valve: its sealing surface is parallel with vertical centerline, which is two
sealing surfaces of the gate valve are parallel. In parallel gate valve, the structure with thrust
wedge is most popular, that is there is a double-surface thrust wedge between the two gates. This
kind of valve is applicable for being low pressure, middle and small diameter (DN40-300mm) gate
valve. Also there are gates valves with spring between its two gate plates, spring can produce
pretension stress, which benefits sealing of gate valve.
b. Wedge gate valve: its sealing surface and it vertical centerline forms a certain angle, which
is two sealing surface form a wedge. The inclined angle is generally 252, 330, 5, 8, 10. The
angle generally depends on medium temperature. The higher the working temperature is, the
bigger than angle is. Wedge gate valves can be divided into single gate valve, double gate valve
and flexible gate valve.
c. Single gate plate is wedge type valve with simple structure and is reliable. It has a high
requirement of precision for sealing surface angle, and it is a little difficult to process and repair, it
is possible to wedge during temperature changing. Double gate plates are commonly used in
pipelines with medium of water and steam. Its advantages are: low requirement of precision of
sealing surface angle, gasket can be used for compensation when sealing surface is abraded. But
this structure has too may parts, in which glutinous medium can be easily felted. Whats more, rust
may easily occur to upper and lower damper and gate plate drops easily. Flexible single gate plate
has been improved on its process and now is widely adopted.
4.2.2.2 It can be divided into according to structure of valve stem.
a. Inside screw non-rising stem type gate valve: valve stem nut is on valve cover, screw valve
stem nuts to lift and lower as illustrated in figure 3.
b. Outside screw rising stem type gate valve: Valve stem nuts are in valve body and contact
with medium directly. Gate plate is opened and closed through revolving stem as illustrated in
figure 4. The advantage of the structure is: the height of gate valve is always the same, thus its
installation space is small. It is suitable for being used as big diameter gate valve or that with
limited installation space. Closing and opening indicator is installed for this structure to indicate
openness. The disadvantage of this structure is: valve stem can not be lubricated and contacts
with medium directly, thus it can be eroded easily.
4.2.3 Gate valve structure sketch map:
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4.2.2.1 Clean parts of valve body, valve cover, valve element, valve seat and valve stem.
4.2.2.2 Check abrasion, corrosion and damage conditions of parts; fix or replace damaged parts.
4.2.2.3 Check erosion, abrasion, corrosion and damage of sealing surface of valve element and
valve seat; grind the sealing surface.
4.2.2.4 Replace stuffing material and filling up material of all sealing surfaces.
4.2.2.5 Valve tightness test.
4.3 Stop valve maintenance
Stop valve is a kind of valve that closing piece (valve clack) moves along centerline of valve
seat, it is mainly used for cutting in pipeline.
4.3.1 Stop valve advantages and disadvantages
Compared with gate valve, the opening height of stop valve is small and its opening time is
short, friction of its sealing surface is smaller than gate valve during opening and closing, and it is
convenient for maintaining. Its disadvantage is that its sealing performance is not good, its fluidity
resistance is big, its torque moment for opening and closing is big and its structure is long.
4.3.2 Stop valve sort
4.3.2.1 According to screw thread position on valve stem, stop valves can be divided into outside
screw stem valve and inside screw stem valve.
a. Outside screw stem valve: screw thread of valve stem is outside valve body. Its advantage
is that valve stem will not be eroded by medium and is convenient for lubrication. This structure is
widely adopted.
b. Inside screw stem valve: screw threads of valve stem are inside valve body. The screw
thread of valve stem of the structure contacts with medium directly, it is easily eroded and can not
be lubricated. This structure is applicable for small diameter valves and places where temperature
is not too high.
4.3.2.2 Sealing surfaces of valve clack can be divided into plane and conical surface.
4.3.3 Stop valve structural sketch map
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4.4 Check valve
Check valve means a kind of valve that close and open valve clack by medium flow to avoid
refulgence of medium.
4.4.1 Check valve sorts
Check valves can be divided into swing check valve, lift check valve, wafer type butterfly
check valve and wafer type round check valve.
4.4.1.1 For lift check valve, valve clack slides along vertical centerline of of valve body, it can only
be install on horizontal pipeline, valve clack on high pressure and small diameter check valve may
adopt round ball. Valve body of lift check valve is same with that of stop valve, thus resistance
coefficient of its fluidity is high.
4.4.1.2 For swing check valve, valve clack revolves around pin shaft outside valve seat; it can be
installed on horizontal and vertical pipelines. It is widely used due to its simple structure.
4.4.1.3 For wafer type butterfly check valve, valve clack revolve around valve seat, its structure is
simple. It can only be installed on horizontal pipelines, but its sealing is not so good.
4.4.2 Check valve structural sketch valve
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Swing Check Valve Lift Check Valve
Wafer type butterfly check valve Wafer type round check valve
English
Double-ended nut
Nut
Valve cover
Gasket
Pin
Swinging arm
Nut
Cotter pin
Gasket
Valve clack
Seat ring
Valve body
Gasket
Shaft
Valve body
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Valve clack
Spring
Valve seat

4.5 Ball valve maintenance
Ball valve is a kind of valve to close and open by revolving closing piece (hollow ball) around
centerline of valve body. It is mainly used to cut, distribute and change medium flowing.
4.5.1 Ball valve characteristics
4.5.1.1 Flow resistance is small; its resistance coefficient is equal to pipe section with same length.
4.5.1.2 Its structure is simple, cubage is small and weight is light.
4.5.1.3 It is tight and reliable; it is also widely used in vacuum system.
4.5.1.4 It can be opened or closed rapidly; it is only need to revolve 90 (convenient for remote
control) from full opening to full closing
4.5.1.5 It is convenient for repairing. Ball valve structure is simple and sealing ring is movable
generally; it is convenient for demounting and replacing.
4.5.1.6 When it is fully opened or closed; ball and valve seat are isolated from medium. When
medium flows through, it will not erode valve sealing surface.
4.5.2 Ball valves can be divided into floating ball valve and fixed ball valve according to fixing type.
4.5.2.1 Floating ball valve
Ball of ball valve is floating. Under pressure of medium, ball can produces a certain
displacement and presses on sealing surface of outlet end tightly to ensure sealing at outlet end.
Floating ball valves structure is simple and its sealing is good. It is widely used for being middle
pressure and low pressure ball valve.
4.5.2.2 Fixed ball valve
Ball of fixed ball valve is fixed and does not displace under press. All fixed ball valves are with
floating valve seat, valve seat displaces after medium pressure to make sealing press on ball
tightly for ensuring sealing. Bearings are installed on upper and lower shaft of ball, its operation
torque is small and it is suitable to be used for being high pressure and big diameter valves.
4.5.3 Structural sketch map
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Floating screw ball valve Floating flange ball valve
English
1 Stuffing pressing cover 1
910 Stuffing material 9, 10
8 Stuffing gasket 8
7 Nuts 7
6 Bolts 6
2 Valve cover 2
13 Spanner 13
12 Valve stem 12
1 Valve body 1
4 Valve element 4
3 Sealing ring 3
5 Regulation gasket 5
Limit block
Stuffing material pressing cover
Stuffing material
Valve body
Valve stem
Ball body
Valve seat
Gasket
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Double-ended bolts
Nuts
Spanner
Spring closing ring
Stuffing material pressing ring
Valve stem bearing
End thrust bearing
Spring
4.5.4 Maintenance item

4.5.4.1 Clean parts such as valve body, cover, element, seat and stem etc.
4.6 Butterfly valve maintenance
Butterfly valve is a kind of valve to close and open or regulate by revolving butterfly plate around
fixed shaft.
4.6.1 Butterfly characteristic and purpose
Butterfly is with small shape and it is convenient for dismantling, installing and maintaining; its
structure is simple and compact. It can be opened or closed rapidly; it is only need to revolve 90
(convenient for remote control) from full opening to full closing. Butterfly valve is suitable for being
valves of all diameters and is generally used in water and air for cutting and throttling. It is not
suitable to be used in high temperature, high pressure pipeline system.
4.6.2 Structural sketch map
English
Couple-ranged butterfly valve
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Valve body
Valve stem
O O type sealing ring
Valve seat
Valve plate
Pin

4.6.3.1 Check and clean abrasion and corrosion of valve body, rubber sleeve of valve seat, valve
element and valve stem.
4.6.3.2 Replace sealing rubber ring of valve seat, stuffing material and filling material of all sealing
surfaces.
4.7 Maintenance of self-acting pressure regulation valve
It is not necessary to add energy source from outside, it introduces the medium to be regulated
by its own power energy to the position of valve element to change the differential pressure and
flow at two ends to make pressure before (after) valve be stable. It has advantages of sensitive
action, nice sealing and small fluctuation of pressure setting values. It is widely used in pressure
decreasing & stabilizing and pressure releasing & stabling automatic control devices with medium
of gas, liquid and steam.
4.7.1 Working principle of self-acting pressure regulation valve
When reducing valve is at free state, valve clack is at close state. Screw down regulation bolts,
valve clack opens (for reducing valve, impulse valve opens firstly and then open valve clack of
main valve through piston), medium flows through valve seat and then out form valve. When
pressure after valve exceeds regulated value, medium pressure acts rightabout on sensors such
as spring, film, piston mechanism, lever mechanism and ripple pipe, which counteracts a part
force of medium to valve clack before valve, valve openness decreases and pressure after valve
decreases accordingly. Pressure acting on sensors also decreases, which makes openness of
valve clack increases again. Thus pressure after valve always fluctuates within a certain range.
4.7.2 Structural sketch map of self-acting pressure regulation valve
4.7.3 Maintenance items of self-acting pressure regulation valve

4.7.3.1 Clean parts such as valve body, cover, element, seat and stem etc.
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4.8 Maintenance of dome valve
Dome valve is an important component in dry ash handling system; its valve element is a ball
dome. During opening and closing, a 2mm clearance is kept between valve element and rubber
sealing ring to make valve element and rubber sealing ring move with no touching, its purpose is
to make in-between of valve element and rubber sealing ring be free from friction and to reduce
abrasion. When dome valve is at closing state, rubber ring is fully filled with air and pressing on
valve element of ball dome tightly, which forms a reliable sealing ring belt and has stopped
material flowing in pipeline.
4.8.1 Structural characteristic of dome valve:
4.8.1.1 Be able to start and close with no friction, which makes mechanical action of valve is
convenient and prolongs its life.
4.8.1.2 Materials can flow smoothly, after opening; valve element can turn to valve chamber side,
which has avoided abrasion to sealing surface of valve element.
4.8.1.3 Judge sealing ring completeness through supervising sealing pressure of sealing ring.
4.8.1.4 Sealing ring life is as long as more than 1 year.
4.8.2 Structural sketch map of dome valve
Dome valve closing state Dome valve opening state

4.8.3 Dome valve maintenance item
4.8.3.1 Clean valve inner chamber, air room of sealing and replace damaged sealing ring.
4.8.3.2 Repairing welding, grinding should be done for abraded and damaged valve element.
5. General Overhaul Process and Quality Standard for Valves
5.1 Safety valve calibration and repair
5.1.1 Significance and method calibrating pressure regulation of safety valve returning to seat
National definition of resetting pressure means safety valve reaches to discharging state,
medium pressure drops to a certain value, valve clack and valve seat contacts again, that is
starting height is zero.
5.1.1.1 Regulation method
Resetting pressure is regulated by regulation ring; the regulation principle is clearance principle.
When spraying resistance is bigger, the dropping force holding valve element is bigger and the
harder for resetting; contrarily, the bigger clearance is, the easier valve element returns and the
higher resetting pressure is. For the safety valve with only downward regulation ring, regulation
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ring is regulated upwards, resetting pressure drops; regulation ring is regulated downwards,
resetting pressure rises. For the safety valve with upward and downward regulation ring, the
distance of upper and lower regulation rings decreases, resetting pressure decreases; the
distance of upper and lower regulation rings increases, resetting pressure rises.
5.1.1.2 Verifying methods and its advantage & disadvantage
Safety valve verifying methods can be divided into site verifying (online verifying) and platform
verifying.
a. Site verifying advantages: it is convenient to verify jointing type safety valve, it can measure
resetting pressure; its disadvantage is: verifying time is long, system should be increased by
pressure repeatedly, it is not economical and dangerous, it can not do sealing test.
b. Air, nitrogen and water are taken as medium for normal temperature verifying of safety
valve. Its advantage is: it can solve safety valve setting and leakage checking under working
temperature of 250C, it can confirm minimum error range of starting pressure of safety valve, it
has saved safety valve installing time and regulation, it has decreased work labor, reduced energy
consumption and danger, its disadvantage is: error exists under running temperature and normal
temperature (spring softens under high temperature), it can not verify resetting pressure.
5.1.1.3 Verifying principle of safety valve
When medium with pressure enters into inlet of safety valve, medium pressure rises and
safety valve is at open state, measure the pressure; record starting pressure and regulate it until
regulated starting value, that is verifying of starting pressure is completed. When pressure drops to
regulated value (90% of starting value), watch pressure meter or other method to check whether
there is medium leakage; that is sealing test.
5.1.1.4 HP verifying characteristic and notices
Safety valve opening sound is very big, especially the big diameter valves, maintenance
personnel should wear earplug.
Vibration is very high when opening HP safety valve.
Impulse force is very big during opening, materials of flange connections should be high
quality.
Spring regulation should not be great and only can be slight.
Air flow and water flow must be filtered.

5.1.2 Repair of safety valve
Repair of safety valve is mainly to repair sealing surface of safety valve, material of which
should be in high quality, its basic requirements are as following: be with high intension and be
able to bear high sealing specific pressure; be with a certain toughness and be able to endure
resetting impact of valve element; be with high rigidity and be able to bear erosion of medium; it
should not rust, otherwise it will leak very soon; be able to bear high temperature and be
applicable to steam etc; be corrosion resistant and be able to bear erosion of acid and alkali. Main
types of hard sealing of safety valve are: plane sealing, taper sealing and ball sealing; the mostly
used is plane sealing.
5.1.2.1 Repair of sealing surface of safety valve
Sealing surfaces of safety valve can be divided into metal type and nonmetal type. Nonmetal
sealing is generally used for normal temperature medium and metal sealing is generally used fro
medium with high temperature and high pressure. When nonmetal sealing surface is damaged,
sealing ring is generally to be dismantled for replacement, it can only be processed by turning if it
can not be dismantled or it has no spare parts. Grinding is adopted when metal sealing surface
damage is not severe. Grinding can be divided into coarse grinding and fine grinding. Valve seat
and valve element must be separated by grinding tool for grinding.
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5.1.2.2 Grinding tool, material
Grinding tool: Grinding flat: a. cast iron (for coarse grinding); b. hard alloy (for fine
grinding) grinding (for grinding valve seat)
Grinding material: oxide chrome, white corundum, 280#, 360#, 600#, W4, W2.5, W1.5
Grinding abrasive: oleic acid, machinery oil, rope oil, lard
5.1.2.3 Sealing surface grinding
Grinding is a method to cut the working surface slightly by using grinding tool and grinding
agent to obtain a higher smoothness and fineness of the surface. The process is called grinding.
Principle of grinding: during grinding, part abrasive is embedded into grinding tool after
bearing a certain press from work piece and grinding tool. When grinding tool and work piece
move oppositely, grinding material slide and rolls between them and produces cutting, which
grinds a layer of protruding of workpiece surface? At the same time, abrasive forms a layer of
oxidation film quickly under effect of chemistry.
5.2 Clean valve mechanical parts
Mechanical cleaning is an important step of repair after dismantling valve. Cleaning method
and quality has great influence on parts rightness, requirement quality, repair cost and its life. Parts
to be cleaned includes cleaning oil dirty, water scale, accumulated carbon, rust and old painting
layer.
5.2.1 Degrease
Clean oil dirty on parts with detergent such as machinery solvent, alkali solution and
chemical detergent. Methods are scribing, baptism and spraying. Cleaning types are artificial
cleaning and mechanical cleaning.
5.2.1.1 Scrubbing
Scrubbing is usually used during mechanical equipment repair that is put part into vessels
filled with kerosene, light diesel oil or chemical detergent and then scrub with cotton yarn or brush
with hair brush to remove oil on parts surface. This method is easily operated and its equipment is
simple, but its efficiency is not high. It is used for degreasing of middle & small size parts and
working surface of large parts. Generally, gasoline is not good to be used as detergent, which may
hurt personal health and cause fire easily.
5.2.1.2 Spraying cleaning
Spraying is to spray detergent with a certain pressure and temperature to parts surface to
clean oil dirty. This method has a good effect and high productivity, but equipments are complex, it
is suitable for cleaning parts with simple shape and heavy oil dirty o surface.
5.2.1.3 Selection of detergent
Different detergents should be used to clean parts made from different materials and oil dirty
produced by different lubricants. Alkali solution is suitable for cleaning animal and plant oil, but
alkali solution has different degrees corrosion to different metals, especially for aluminous. Thus,
different prescriptions should be adopted for cleaning different metal parts.
5.2.2 Removing rust
To ensure repair quality, corrosion on surfaces of parts must be cleaned completely, such as
rust on surface of steel accessory. According to specific conditions, mechanical and chemical
methods are mainly used at present.
5.2.2.1 Mechanical method for removing rust
Clean the rust on surface of parts with effects of mechanical friction and cutting. Common
methods are brushing, grinding, polishing and spraying sand. Artificial polish can be adopted for
single or small amount; mechanical method for cleaning rust can be adopted for large part, such
as electric grinding, polishing and rolling. Spraying sand method is to spray sand with certain
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particle onto parts surface by using compressed air; these methods not only can remove rust
quickly but also prepares for processes such as painting, galvanization etc. The surfaces dealt
with spraying sand can meet the requirements of being clean and with certain coarseness, which
improves combination force between covering layer and parts.
5.2.2.2 Chemical method for removing rust
Dissolve oxide on metal surface by using acid solution to remove rust. The chemical
solutions used presently are mainly sulphuric acid, hydrochloric acid, phosphoric acid or their mixed
solution with a little corrosion inhibitor. Its process is: degreasing, water flushing, removing rust, water
flushing, neutralization, water flushing and removing hydrogen. To ensure effect of rust removing,
solution is generally heated to a certain degree, control the time strictly; proper description should be
adopted according to different materials of parted to be cleaned.
5.3 Valve grinding
5.3.1 Clean and check
Put sealing surface into oil plate and use special detergent, checking its damage condition
while cleaning it. Imperceptible cracks that are difficult to confirm with naked eye can be done with
dye-penetrate destructive method. Check the sealing surface between valve clack or gate valve and
sealing surface of valve seat; red and pencil should be used during checking. Test red with red lead and
check sealing surface to confirm its condition, or draw several concentric rounds on sealing surfaces of
valve clack and valve seat, revolve valve clack and valve seat, check rounds and confirm its condition.
If the tight combination is not good, inspect valve clack and gate plate sealing surface with standard
plane plate to confirm parts to be grinded.
5.3.2 Grinding
Grinding is a cutting process without lathe. Generally depths of blow spots or holes on valve
head or valve seat are generally within 0.5mm; grinding can be adopted for maintenance. Grinding
process can be divided into coarse grinding, middle grinding and fine grinding.
Coarse grinding is to eliminate contusion, impress and corrosion points to make sealing
surface be with a high smoothness and a certain degree of finish to offer a foundation for middle
grinding of sealing surface. Coarse grinding uses grinding head or grinding seat tools and adopts
coarse sand paper or coarse grinding paste with granularity of 80#-280#. Thus, coarse grinding is
only to remove blow spots on valve head or seat smoothly.
Middle grinding is to eliminate coarse lines on sealing surface to improve smoothness and
degree of finish fatherly. Fine sand paper or fine grinding paste with granularity of 280#-W5, which
benefits to decrease coarseness. Related grinding tools should be replaced and the tools should
be clean. After middle grinding, contacting surface of valve should be in brightness. If draw lines
on valve head or valve seat with pencil and then turn valve head or valve seat oppositely and
slightly, the pencil lines should be erased.
Fine grind is the last process of grinding to improve fineness. W5 or thinner grinding sand is
diluted with machinery oil and kerosene, grind valve seat with valve head but not grinding tool,
which benefits combination of sealing surface. Generally, it turns about 60-100 clockwise and
then 40-90 anticlockwise, check it after a while until it is grinded to be in brightness and a ring of
fine line can be seen on valve head and seat and its color is black and bright, grind it slightly with
machinery oil for several and then wipe it clean with clean gauze. After grinding, clean other
defects and they assemble it as soon as possible to avoid damaging a grinded valve head.
No matter it is coarse grinding or fine grinding of manual grinding, it is always the grinding
process combined with lifting up, lying down; revolving to and fro; knocking and transferring
direction. Its purpose is to avoid repeated trace of grinding granularity to make grinding and
sealing surface get even cutting and to improve smoothness and fineness of sealing surface.
5.3.3 Inspections during grinding
Inspections should be done frequently to acknowledge grinding conditions and to make
grinding quality meet requirements. It should be noted that grinding of different valves should
adapt grinding tools of different sealing types to improve grinding efficiency and quality.
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Valve grinding is a meticulous work, it is required to experience, feel around and improve;
sometimes, it is grinded very well, but it still leaks steam and water after installation, this is
because that inclined grinding occurs during grinding.
5.4 Dismantling and installing of valve stuffing material
Valves generally adopt stuffing sealing type; after a period of service, its flexibility and
lubrication effect will lose. Liquid may leak in and air may enter into valve if it is not replaced timely.
Thus, stuffing material of sealing device should be replaced during maintenance. It also should be
replaced if it leaks badly due to bad quality or installation.
5.4.1.2 Parts should be replaced if abrasion of pressing cover, closing sleeve or rings of stuffing
material is excessively abraded.
5.4.1 Demounting of stuffing sealing device
5.4.1.1 Loosen pressing cover nuts of stuffing housing slowly, release residual pressure in gland
packing.
5.4.1.2 Take out all oil gland packing with tool or iron hook, clean shaft/stem in stuffing housing
completely.
5.4.1.3 Check whether shaft/stem has corrosion, indention, scar or abrasion or not.
5.4.1.4 Check whether other parts have burr, crack and abrasion or not. They may shorten gland
packing life.
5.4.1.5 Check whether clearance of stuffing housing is too big or not; check shaft/stem
eccentricity.
5.4.1.6 Replace parts with great defects.
5.4.2 Stuffing material assembling
Assembling quality is closely related to sealing effect of sealing, following points should be
noted during stuffing assembling:
5.4.2.1 Cut should be regular when cutting stuffing material, there is no loosened asbestos head;
interface should be formed into angle of 30~45.
5.4.2.2 Lubricant should be spreaded on each stuffing ring, which ia separately pressed into
stuffing housing. During installation by pressing, cuts of stuffing ring must stagger; generally
interfaces of neighboring stuffing rings should stagger 120.
5.4.2.3 Water sealing ring should aim at liquid sealing pipe, it may be moved outwards 3~5mm by
considering that stuffing material should be pressed continuously after installing stuffing pressing
cover.
5.4.2.4 After filling stuffing material, bolts at two sides of pressing cover should be evenly screwed
down but not too much to avoid losing flexibility of stuffing material, which may add abrasion of
shaft sleeve (or shaft, valve stem)and power consumption.
5.4.2.5 The depth of stuffing material pressed into stuffing housing is height of one ring stuffing
material generally but not less than 5mm. A certain distance should be kept between cover plate of
stuffing material and stuffing housing for the convenience of continuous pressing stuffing material
tightly.
5.4.3 Notices of stuffing material installation and repairment
Stuffing pressing cover should be dismantled firstly during during stuffing filling and
repairment, then take out old stuffing material, clean all parts, then fill in new stuffing materials and
check clearance between all parts. When clearance between closing ring and shaft sleeve (shaft
or valve stem) is too big, stuffing material in housing may be pressed out. When the clearance
between outer round surface of pressing cover of stuffing housing and inner round surface is too
big, pressing cover may be pressed to be inclined. Inner round surface of stuffing pressing cover
and outer round surface of shaft sleeve (or shaft, valve stem) must keep in concentric, if the
clearance is too small, friction with shaft (or shaft, valve stem) may occur easily. All the above
289
clearance should comply required standards strictly, it must be repaired or replaced if it doent.
5.5 Sealing gasket installation
Gasket type to be adopted is confirmed according to nominal pressure, medium
characteristic and maximum temperature. Sealing gaskets can be divided into: nonmetal gasket
(flexible graphite type, PTFEF4 type, rubber type and non-asbestos fibre type), metal gasket
(Stainless steel serrated gasket, soft metal gasket and lens gasket) and composite gasket (stainless
steel gasket wound with graphite, stainless steel spurt graphite plate).
5.5.1 Check before installation
5.5.1.1 Check gasket
a . Gasket type, material and dimension should comply with requirements.
b. Gasket surface should be free from mechanical damage, radial scar, rust or inner & outer
edge dilapidation.
c. Gasket selected should be suitable for sealing surface type of flange.
5.5.1.2 Check bolts and nuts
a. Bolts and nuts type, material and dimension should comply with requirements.
b. Nuts can be turned freely on bolts bu with no swinging.
c. Bolts and nuts should be free from scar or burr.
d. Breaking is not allowed for screw threads.
e. Screw threads should be free from bending.
5.5.1.3 Check flange
Check that flange type should comply with requirement, sealing surface should be smooth
and free from mechanical damage, radial trace, rust, welding scer or burned oil vestiges, specific
methods should be researched if it can not be repaired.
5.5.1.4 Check pipeline and flange installation quality before flange gasket, following defects should
not exsist:
a. Piplines are neither vertical nor concentric and flanges are not parallel. Permit inclined
value between flanges is as following: it should be less than 2mm when suing nonmetal gasket
and it should be less than 1mm when using semi-metallic gasket, ellipse gasket and equipment
connection flanges.
b. Pipeline and flange are vertical but not concentric. Under condition that diameters of bolts
holes and bolts comply with standard, it is deemed as to be qualified when bolts can go into bolts
freely without tools.
c. Flanges clearance is too big. Permit value between flanges is as following: pipe flange
dehiscence should be less than 3mm and dehiscence of flanges connecting to equipments should
be less than 2mm.
d. Pipeline and flange are concentric, chord-distance of related bolts holes of two flanges should
not be bigger than 1mm.
5.5.2 Instalaltion
5.5.2.1 Gasket should be preserved well.
5.5.2.2 Two flanges must be on same centerline and in parallel.
5.5.2.3 Clean flange sealing surface and sealing line caerefully before installation.
5.5.2.4 Only one gasket can be added between two flanges, more than one gasket used to be
added between two flanges to clean defect is not allowed.
5.5.2.5 Gasket must be installed rightly and with no deflection to ensure press even and to avoid
gasket extending into pipe and causing vortex.
290
5.5.2.6 Bolts should be evenly and symmetrically tightened.
291

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Chapter 1 Boiler

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Indonesia 1660MW Paiton

Coal Fired Thermal Power Plant

Operating and Maintenance Manual

Volume III: Maintenance Manual

Harbin Power Engineering Company Limited

June, 5th, 2009

Chapter Boiler Proper Heating Surface Maintenance......................................................... 1

Chapter Maintenance Regulation for Pipes and Valves of the Boiler.............................. 24

Chapter Maintenance of Burner and Oil Gun.................................................................. 57

Chapter Soot Blower Maintenance ................................................................................. 64

Part Two Boiler Auxiliary Equipment Maintenance.................................................................... 74

Chapter Coal Mill Maintenance ......................................................................................... 74

Chapter Boiler Coal Feeder Overhaul.............................................................................. 98

Chapter Boiler Raw Coal Hopper Maintenance Regulation.......................................... 112

Chapter Air Compressor Overhaul................................................................................ 113

Chapter Boiler Mill Sealing Air Fan Maintenance Regulation....................................... 127

Regulation ............................................................................................................................. 130

Chapter Air Preheater Maintenance Regulation.......................................................... 162

Part Three Ash Handling System Equipment Maintenance Regulation.................................. 203

Chapter Slag Removing Equipments Maintenance Regulation........................................ 203

Chapter Dry Ash Transportation Equipments Overhaul ................................................ 239

Chapter Pipeline System and Valve Maintenance ....................................................... 272

Chapter Boiler Proper Heating Surface Maintenance

Technical Supervision Codes for Metal in Thermal Power Plants DL 4382000

. B&WB-2028/17.5-M Boiler Brief Introduction

Superheater outlet steam temperature 541

Reheater steam flow t/h 1839.8

Reheater inlet steam temperature 338.1

Reheater outlet steam temperature 541

Economizer inlet feedwater temperature 281.4

Boiler barrel design pressure MPa(g) 19.9

Name Unit TMCR (660MW)

Superheater outlet steam temperature 541

Reheater steam flow t/h 1742.4

Reheater inlet steam temperature 332.3

Reheater outlet steam temperature 541

Economizer inlet feedwater temperature 282.7

Attemperator water temperature (HP heater inlet) 281.4

Boiler barrel design pressure MPa(g) 19.9

. Boiler Proper Maintenance

Downcomer pipe tie-in

3.1.3.2.5 Rear panel superheater

Boiler barrel Horizontal low temperature

Saturation steam Vertical low temperature

Roof pipe inlet pipe Vertical low temperature

Roof pipe First stage attemperator inlet

Roof bypass pipe Superheater first stage

Roof outlet header First stage attemperator

Enclosure wall system Splitter plate inlet header

Rear gas duct roof pipe Superheater splitter plate

Rear gas duct rear wall Splitter plate outlet header

Rear gas duct rear wall Connection pipe between

Rear gas duct side wall Rear plate inlet header

Rear gas duct rear Superheater rear plate

Rear gas duct front wall Rear outlet header

Rear gas duct extending Superheater second stage

Rear gas duct side wall Second stage attemperator

Rear gas duct extending Final stage superheater inlet

Rear gas duct front Final stage superheater

Rear gas duct side wall Final stage superheater

Low temperature Superheater outlet guide

Cold wall reheater pipe

Reheater spray water attemperator

Cold section reheater pipe