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Document Coversheet

Document designation: Lances


Operation and Maintenance Manual

Leading Code 11HTQ20BN001


___________________________________________________________________________

Codes which are also 11HTQ20BN002


applicable: 11HTQ20BN003
11HTQ20BN004
11HTQ20BN005
21HTQ20BN001
21HTQ20BN002
21HTQ20BN003
21HTQ20BN004
21HTQ20BN005

Rev Issued Prepared Check Q-Check Approval Description

00 14.04.2015 J.Barthel G.Frick - - First Issue

01

02

FGD CFB Cochrane A.23001 A.23001-0-05330-MTD-LUE-0001 00


Plant Order No. Document Number Rev.
Operation and Maintenance Manual
Cochrane
Spillback Nozzle Lances

READ THESE INSTRUCTIONS BEFORE PERFORMING ANY WORK


KEEP INSTRUCTIONS AS A REFERENCE

Operation and Maintenance Manual


Spillback Nozzle Lances
800.117.82.00.00.0

Manufacturer:
Lechler GmbH
Precision Nozzles – Nozzles Systems
Ulmer Str. 128
72555 Metzingen / Germany
Phone: +49 (0) 7123 / 962 – 0
Fax: +49 (0) 7123 / 962 – 301

Rev. Date Prepared Date Checked Date Q-Management Released Revised

00 09.04.2015 J.Barthel 10.04.2015 G.Frick

Document No. Contractor: A.23001-1-05330-MOM-LUE-0002 Rev. 1 of 99


Document No. Employer : 62-13-132-1_l_oi_v0_15-04-10 00
© The content of these documents are the sole property of Doosan Lentjes GmbH. Any rights not expressly granted herein are reserved.
Reproduction, transfer or distribution of part or all of the contents in any form without prior written permission of Doosan Lentjes GmbH is
prohibited.
Operation and Maintenance Manual
Cochrane
Spillback Nozzle Lances

Table of content
1  About this operating instructions........................................................................ 6 
1.1  Adherence to the operation manual ........................................................................ 6 
1.2  Further applicable documents ................................................................................. 6 
1.3  Information about illustrations ................................................................................. 6 
1.4  Symbols used in this operation manual................................................................... 6 
1.4.1  Warning notices.................................................................................................. 7 
1.4.2  Further information ............................................................................................. 7 

2  Safety...................................................................................................................... 8 
2.1  Intended use............................................................................................................ 8 
2.2  Prohibited operating conditions ............................................................................... 8 
2.3  Responsibilities of the operator ............................................................................... 9 
2.4  Staff qualifications ................................................................................................. 10 
2.5  Personal protection and safety measures at the workplace .................................. 11 
2.6  General dangers.................................................................................................... 11 
2.6.1  Danger of death due to operating media under high pressure ......................... 11 
2.6.2  Before starting work on pressurised lines ........................................................ 12 
2.6.3  Assembling/disassembling the nozzle lance in the CFB-reactor ...................... 12 
2.6.4  Spray tests outside the CFB-reactor ................................................................ 12 
2.6.5  Risk of burns from hot surfaces........................................................................ 13 
2.6.6  Risk of injury from noise ................................................................................... 13 
2.6.7  Safety information for transportation ................................................................ 13 
2.6.8  Warning labelling .............................................................................................. 13 
2.7  Safety data sheets................................................................................................. 14 
2.8  Plants and components ......................................................................................... 14 
2.9  Special safety instructions when handling hazardous material ............................. 14 
2.9.1  Safety measures at the workplace ................................................................... 15 

3  General ................................................................................................................. 16 

4  Description........................................................................................................... 17 
4.1  Task of the system ................................................................................................ 17 
4.2  Main components .................................................................................................. 17 
4.2.1  Nozzle lance ..................................................................................................... 18 
4.2.1.1  Mounting flange .......................................................................................... 19 
4.2.1.2  Connections for operating media ................................................................ 19 
4.2.1.3  Nozzle ......................................................................................................... 20 
4.2.2  Water accessories ............................................................................................ 20 

Document No. Contractor: A.23001-1-05330-MOM-LUE-0002 Rev. 2 of 99


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prohibited.
Operation and Maintenance Manual
Cochrane
Spillback Nozzle Lances

4.2.2.1  Supply line .................................................................................................. 22 


4.2.2.2  Return line .................................................................................................. 23 
4.3  Standards and guidelines ...................................................................................... 23 
4.4  Operation description ............................................................................................ 24 
4.5  Function of important equipment ........................................................................... 24 
4.5.1  Dirt trap............................................................................................................. 24 
4.5.2  Gang valve assembly ....................................................................................... 24 
4.5.3  Non-return valve ............................................................................................... 25 
4.6  Technical data ....................................................................................................... 26 
4.6.1  Technical principles Lechler spillback nozzles ................................................. 26 
4.6.2  Design of Lechler nozzle lances....................................................................... 27 
4.6.3  General information on Lechler nozzle lances ................................................. 28 
4.6.4  Water quality .................................................................................................... 28 
4.6.5  Critical temperatures of the parts exposed to high temperatures ..................... 29 
4.6.6  Nozzle parts and materials – data sheet 261.036.1Y.78.00.Z ......................... 30 
4.6.7  Pressure/flow rate diagram 261.036.1Y.78.00.Z .............................................. 31 
4.6.8  Load cases and design data ............................................................................ 32 
4.6.8.1  Single nozzle .............................................................................................. 32 
4.6.8.2  Nozzle lance ............................................................................................... 33 
4.6.8.3  Complete installation .................................................................................. 33 
4.6.9  Main equipment data ........................................................................................ 34 
4.6.9.1  Dirt trap ....................................................................................................... 34 
4.6.9.2  Non-return valve ......................................................................................... 34 
4.6.10 Classifying of pressure equipment according to directive 97/23/EG (PED) ..... 35 

5  Operation Instruction .......................................................................................... 37 


5.1  Installation ............................................................................................................. 37 
5.1.1  Safety information for installation ..................................................................... 37 
5.1.1.1  Securing against unauthorised start-up ...................................................... 37 
5.1.1.2  Excess pressure in the duct ........................................................................ 37 
5.1.1.3  Incorrect installation and initial start-up ...................................................... 38 
5.1.2  Initial installation ............................................................................................... 39 
5.1.3  Adjusting the installation length of the spillback nozzle lance .......................... 39 
5.1.3.1  Checking the installation length .................................................................. 39 
5.1.3.2  Adjusting the installation length .................................................................. 40 
5.1.4  Installing the spillback nozzle lance ................................................................. 41 
5.1.5  Assembling the water accessories at the supply lines ..................................... 45 
5.1.6  Connecting the water accessories to the nozzle lance .................................... 48 
5.1.7  Nozzle lance position ....................................................................................... 53 

Document No. Contractor: A.23001-1-05330-MOM-LUE-0002 Rev. 3 of 99


Document No. Employer : 62-13-132-1_l_oi_v0_15-04-10 00
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prohibited.
Operation and Maintenance Manual
Cochrane
Spillback Nozzle Lances

5.1.8  Electrical connection ........................................................................................ 53 


5.2  Preparation for start-up ......................................................................................... 53 
5.2.1  Flushing the piping with water .......................................................................... 53 
5.2.2  Filling the supply line with water ....................................................................... 53 
5.2.3  Functional Tests ............................................................................................... 56 
5.3  Conditions for start-up ........................................................................................... 56 
5.3.1  Check criteria before commissioning ............................................................... 56 
5.3.2  Valve position list.............................................................................................. 57 
5.3.2.1  Valve position before start-up ..................................................................... 57 
5.3.2.2  Valve position during operation .................................................................. 58 
5.4  Putting the nozzle lance into operation ................................................................. 58 
5.5  Operation............................................................................................................... 59 
5.5.1  Control walkabout............................................................................................. 59 
5.5.2  Check schedule ................................................................................................ 60 
5.5.3  How to react on alarms .................................................................................... 60 
5.6  Shut-down ............................................................................................................. 60 
5.6.1  Putting the nozzle lance out of operation ......................................................... 61 
5.6.2  Disconnect the water accessories .................................................................... 62 
5.7  Spillback nozzle lance removal ............................................................................. 64 
5.8  Frost protection ..................................................................................................... 66 
5.9  Storage when not in use........................................................................................ 67 

6  Troubleshooting .................................................................................................. 68 


6.1  Operation during fault conditions........................................................................... 68 
6.2  Preventive measures to avoid fault situations ....................................................... 68 
6.3  Typical faults and suggested remedies ................................................................. 69 

7  System stand still ................................................................................................ 70 


7.1  Short-term stoppages ............................................................................................ 70 
7.2  Stoppages of up to 48 hours duration ................................................................... 70 
7.3  Stoppages of over 48 hours duration .................................................................... 70 

8  Routine maintenance .......................................................................................... 71 


8.1  Maintenance schedule .......................................................................................... 71 
8.1.1  Adjust the maintenance intervals ..................................................................... 71 
8.2  Safety information for maintenance....................................................................... 72 
8.2.1  Danger from incorrect maintenance ................................................................. 72 
8.2.2  Spray tests outside of the CFB-reactor ............................................................ 73 
8.2.3  Maintenance schedule ..................................................................................... 75 
8.3  Maintenance work ................................................................................................. 76 
Document No. Contractor: A.23001-1-05330-MOM-LUE-0002 Rev. 4 of 99
Document No. Employer : 62-13-132-1_l_oi_v0_15-04-10 00
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Reproduction, transfer or distribution of part or all of the contents in any form without prior written permission of Doosan Lentjes GmbH is
prohibited.
Operation and Maintenance Manual
Cochrane
Spillback Nozzle Lances

8.3.1  Visual inspection .............................................................................................. 76 


8.3.2  Cleaning the nozzle lance ................................................................................ 76 
8.3.3  Spray test ......................................................................................................... 77 
8.3.4  Repairing the sealing surface at the supply pipe.............................................. 80 
8.3.5  Nozzle .............................................................................................................. 80 
8.3.5.1  Disassembling the nozzle ........................................................................... 81 
8.3.5.2  Visual inspection ......................................................................................... 84 
8.3.5.3  Clean the nozzle ......................................................................................... 84 
8.3.5.4  Assembling the nozzle ................................................................................ 85 
8.3.5.5  Checking the nozzle for leaks ..................................................................... 89 
8.3.6  Non-return valve ............................................................................................... 93 
8.3.6.1  Checking for leaks ...................................................................................... 93 
8.3.6.2  Checking for blockages .............................................................................. 94 
8.3.7  Cleaning the strainer ........................................................................................ 95 
8.3.8  Inspecting the high pressure hoses.................................................................. 96 
8.4  Spare parts ............................................................................................................ 97 
8.5  Lubricating/Greasing ............................................................................................. 97 
8.5.1  Spillback Nozzle and Nozzle Lance ................................................................. 97 
8.5.2  Other Equipment .............................................................................................. 98 

9  Appendix .............................................................................................................. 99 

Document No. Contractor: A.23001-1-05330-MOM-LUE-0002 Rev. 5 of 99


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prohibited.
Operation and Maintenance Manual
Cochrane
Spillback Nozzle Lances

1 About this operating instructions

This operation manual contains information on the safe handling of nozzle lances. Make
sure that this operation manual is always available to personnel.

1.1 Adherence to the operation manual

This operation manual applies to the operator as well as all persons involved in the
transport, assembly, disassembly, operation, repair and disposal of nozzle lances. Each of
these persons is obliged to read the operation manual carefully before starting work and
observe the instructions.

The local accident prevention regulations and the accepted technical rules for safe and
proper work also apply.

1.2 Further applicable documents

You have been given the following documents in addition to this operation manual. The
information and instructions contained therein must always be observed.

Operation manuals of the suppliers of the individual equipment see documentation part
TD/17.01.

1.3 Information about illustrations

Some of the images in this operation manual show a simplified view of the nozzle lances.
Actual details may differ from those shown in the images.

Detailed views and dimensions of the nozzle lance can be found in the supplied drawings.

1.4 Symbols used in this operation manual

Important information in this operation manual is indicated by specific symbols or special


instructions. Examples of key symbols and their definitions are shown below.

Document No. Contractor: A.23001-1-05330-MOM-LUE-0002 Rev. 6 of 99


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prohibited.
Operation and Maintenance Manual
Cochrane
Spillback Nozzle Lances

1.4.1 Warning notices

Warning notices are intended to help recognise and avoid hazardous situations and
adverse consequences. The warning notices are introduced by signal words which
indicate the severity of the hazard.

The following warning notices are used in this operation manual:

DANGER
This warning notice indicates a hazardous situation which will result in
serious injury or death.
→ The arrow indicates a safety precaution that must be taken to avoid the
hazardous situation.

WARNING
This warning notice indicates a hazardous situation which could
potentially result in serious injury or death.
→ The arrow indicates a safety precaution that must be taken to avoid the
hazardous situation.

CAUTION
This warning notice indicates a hazardous situation which could result in
minor or moderate injury.
→ The arrow indicates a safety precaution that must be taken to avoid the
hazardous situation.

NOTICE
This warning notice indicates a hazardous situation which could result in
damage to, or the destruction of, the nozzles and/or other parts of the
system.
→ The arrow indicates a safety precaution that must be taken to avoid the
hazardous situation.

1.4.2 Further information

TIP
Tips contain further information on handling the nozzle lance. This information is intended
to help avoid problems and facilitate nozzle lance application.

Document No. Contractor: A.23001-1-05330-MOM-LUE-0002 Rev. 7 of 99


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prohibited.
Operation and Maintenance Manual
Cochrane
Spillback Nozzle Lances

2 Safety

The nozzle lances are safe to operate. They have been designed, constructed and
manufactured using state-of-the-art technology.

Nonetheless, nozzle lances can present risks if not used as intended, used incorrectly or
under unsuitable operating conditions.

2.1 Intended use

The nozzle lances are part of the VarioCool® system and are designed exclusively for
injecting water into a duct.

The design and construction of the nozzle lances are tailored to the specific application.
The nozzle lance must only be used under the conditions specified in the operation
manual (4.6 Technical data) and by appropriately trained and qualified staff (2.4 Staff
qualifications).

Any further or additional use of the nozzle lances is not as intended and can result in the
risk of injury, danger of death or considerable damage to property.

2.2 Prohibited operating conditions

Safe operation of the nozzle lances is only guaranteed if they are installed, commissioned
and maintained properly.

Use of the nozzle lances is prohibited in the following circumstances:


- Faults or damage have been detected.
- Maintenance intervals have been exceeded.

Document No. Contractor: A.23001-1-05330-MOM-LUE-0002 Rev. 8 of 99


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Operation and Maintenance Manual
Cochrane
Spillback Nozzle Lances

2.3 Responsibilities of the operator

The operator is bound by the statutory obligations on occupational safety. In addition to


the information on safety in this operation manual, the valid safety and accident preven-
tion regulations as well as the environmental legislation on the area of application of the
nozzle lances must be observed.

In particular, the operator has the following responsibilities:


- To identify risks which result from the working conditions at the site of operation
(risk assessment) and prepare operation manual for use of the nozzle lances.
- To specify responsibilities for all work in connection with the nozzle lances.
- To ensure that all persons who work with or on the nozzle lances have read and
understood this operation manual.
- To train staff regularly on the handling of the nozzle lances (installation, start-up,
operation, maintenance) and inform them of the possible risks. The operator is
recommended to have participants confirm in writing that they have been
instructed on the handling of the nozzle lances.
- Staff that are under instruction or taking part in general educational measures must
be supervised at all times by a suitably trained person when working with the
nozzle lance.
- To ensure that the required personal protective equipment is always available in
perfect condition and used correctly.
- To ensure that suitable lifting equipment, tools, blank flanges, screw connections,
seals and other parts for assembly and maintenance are available and are used
properly.
- To ensure that suitable insulation is fitted to heat-conducting parts.

Furthermore, the operator is responsible for ensuring that the nozzle lances are always in
technically perfect condition. In particular, the operator must guarantee:
- The correct supply and disposal of media.
- That faults are eliminated immediately, in particular those which impair safety.
- That maintenance intervals are observed.
- That safety devices are checked regularly.

Document No. Contractor: A.23001-1-05330-MOM-LUE-0002 Rev. 9 of 99


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Operation and Maintenance Manual
Cochrane
Spillback Nozzle Lances

2.4 Staff qualifications

WARNUNG
Risk from insufficiently trained staff
Insufficiently trained staff is unable to assess properly the risks associated with
handling the nozzle lances. Such persons expose themselves and others to the
risk of serious or even fatal injuries.
→ Only allow work to be performed by sufficiently qualified persons.
→ Insufficiently qualified persons must be kept clear of the area.

All work on the nozzle lances requires that staff have special knowledge and skills.

All persons who work with the nozzle lances must meet the following requirements:
- Physically suitable for the respective task
- Suitably qualified the respective task
- Instructed in the handling of the nozzle lances (installation, start-up, operation,
maintenance)
- Familiar with the operation manual, especially the safety instructions and sections
of the operation manual which are relevant for the specific task.
- Familiar with the applicable documents
- Familiar with the fundamental occupational health and safety rules and regulations
- Familiar with first aid procedures.

Generally speaking, persons working at the nozzle lance must possess the following
minimum qualifications:
- Fully trained and qualified in order to work autonomously with the nozzle lances.
- Having received sufficient instruction to carry out work on the nozzle lances under
the supervision and guidance of a qualified person.

Staff must have knowledge and experience of the following fields:


- Work the dangerous media (hot, subject to pressure).
- Making connections on piping. Selection of suitable screw connections and seals.

Document No. Contractor: A.23001-1-05330-MOM-LUE-0002 Rev. 10 of


Document No. Employer : 62-13-132-1_l_oi_v0_15-04-10 00 99
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Reproduction, transfer or distribution of part or all of the contents in any form without prior written permission of Doosan Lentjes GmbH is
prohibited.
Operation and Maintenance Manual
Cochrane
Spillback Nozzle Lances

2.5 Personal protection and safety measures at the workplace

Personal protection equipment should be kept ready and should be used if necessary:
- Tightly fitting protective goggles
- Mouth protection
- Hand protection
- Eye protection.

Personnel must always wear suitable protective clothing during inspection, repair and
maintenance e.g. tightly closing work clothes, safety boots, protective gloves, goggles,
hard hat etc. during inspection, repair and maintenance of the spillback nozzle lances.

Change contaminated clothing immediately after completing the work. Store working
clothes and your normal clothes separately.

It’s forbidden to consume or store food or drinks in the danger area.

Obtain the telephone number of the nearest local hospital or doctor. The responsible shift
manager should know this numbers.

Wash skin thoroughly with water and soap after work. Apply protective cream.

Action in case of fire or damage:


- Use dry fire extinguisher.
- Wear goggles and respiratory mask, if necessary.

2.6 General dangers

2.6.1 Danger of death due to operating media under high pressure

Nozzle lances are used with operating media subject to high pressure.

Pressurised nozzle lances and other lines may move in an uncontrolled manner and
cause serious or even fatal injuries if they are defective or not used properly.

Medium can emerge at high pressures from pressurised components if they are not used
properly or if they are defective resulting in serious or even fatal injuries.

The following applies for all work on the nozzle lances:


→ Work with the utmost care and attention to detail.
Document No. Contractor: A.23001-1-05330-MOM-LUE-0002 Rev. 11 of
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Operation and Maintenance Manual
Cochrane
Spillback Nozzle Lances

→ Always use suitable protective equipment.

2.6.2 Before starting work on pressurised lines

1) Depressurise the system.


2) Allow heat-carrying lines to cool down.
3) Check that the system is depressurised, if necessary by carefully opening one of the
connections.

Always ensure that the medium cannot escape unintentionally:


→ protect shut-off devices from being opened accidentally,
→ secure auxiliary lines,
→ seal off any openings using suitable blank flanges,
→ position warning signs, e.g., "Maintenance work. Do not open!"

2.6.3 Assembling/disassembling the nozzle lance in the CFB-reactor

If there is excess pressure in the CFB-reactor, hot, dust-laden gas can escape from open
mounting tube. This may result in serious or even fatal burns.
→ Work with the utmost care and attention to detail.
→ Always use suitable protective equipment.
→ Protect your face. Never look directly into the mounting tube. Never stand directly in
front of the opening.
→ Close the mounting tube with a suitable blank flange.

2.6.4 Spray tests outside the CFB-reactor

Incorrect spray test may result in serious injury or even death. Furthermore, this could
result in considerable damage to property:
→ Always adhere to the instructions in these operating instructions.
→ Always use suitable protective equipment.
→ Never direct the flow of liquid at persons.
→ Never hold your hand in the flow of liquid if the nozzle lance is being operated at a
high pressure or temperature.
→ Ensure that the operating media are conducted away safely. Never direct the jet at
sensitive system components, acid baths or similar.
→ Ensure that all parts are properly secured. Only disconnect the high pressure hoses
from the nozzle lances when the former are depressurised.
→ Use safety operating media.

Document No. Contractor: A.23001-1-05330-MOM-LUE-0002 Rev. 12 of


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Operation and Maintenance Manual
Cochrane
Spillback Nozzle Lances

2.6.5 Risk of burns from hot surfaces

Nozzle lances get very hot in the hot gas flow. There is risk of burns in case of contact
with the surfaces.
→ Always use suitable protective equipment.

2.6.6 Risk of injury from noise

The nozzle lances generate noise when in operation. This may result in damage to
hearing.
→ Wear suitable ear protection.

2.6.7 Safety information for transportation

Because of the weight of the nozzle lance Lechler GmbH recommends to use suitable
facilities like e.g. a lifting block for safeguarding during any kind of activities with the
nozzle lance.

If lifting is not performed properly, loads could swivel out and fall down. This can result in
serious injury or even death.
→ Never stand under suspended loads.
→ Only move loads under supervision.
→ Only use approved lifting equipment and load suspension devices with sufficient load
carrying capacity

Packages may have an eccentric centre of gravity. If fastened incorrectly, the package
can tip over and fall down. Serious injuries can result from packages which topple over/fall
down.
→ Secure loads safely, use suitable attachment points.
→ When transporting loads with a crane, fasten the hook so that it is positioned over the
centre of gravity.
→ Lift the package carefully and monitor whether it tilts over. If necessary change the
attachment point.

2.6.8 Warning labelling

Labels may become soiled or illegible for other reasons over the course of time. As a
consequence the risks may not be recognized resulting in serious injuries.
→ Make sure that all labels always remain legible.
→ Replace damaged labels immediately

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Operation and Maintenance Manual
Cochrane
Spillback Nozzle Lances

The following warning label is attached to the mounting flange:


DANGER Do not disconnect hoses under pressure. CAUTION Hot surface.

Warning label on mounting flange

2.7 Safety data sheets

Not applicable

2.8 Plants and components

Refer to chapter 4.2 on page 17.

2.9 Special safety instructions when handling hazardous material

If the spillback nozzle lances are operated with aggressive, corrosive, hazardous or
environmentally unfriendly liquids, the nozzle lance liquid lines must also be flushed
through with water after being blown through with atomizing air before being removed.

All operating procedures must be observed.

The safety measures described below are only recommended and whether they are used
should be decided on site from case to case. The measures also apply similarly to units
which are not described in this chapter.

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Operation and Maintenance Manual
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Spillback Nozzle Lances

2.9.1 Safety measures at the workplace

Technical:
- Isolate the electrical components and secure them against unauthorized use
before any kind of inspection, repair and maintenance.
- Close the gang valve assembly (A.23001-1-05330-MDD-LUE-005
(9ET.084.40.XY.08.0-DE-AV1-DE-01) – pos. 1) before any kind of repair and
maintenance for the accessories and secure them against unauthorized use.
- Close the gang valve assembly (A.23001-1-05330-MDD-LUE-005
(9ET.084.40.XY.08.0-DE-AV1-DE-01) – pos. 1) before any kind of repair and
maintenance for the spillback nozzle lances and secure them against unauthorized
use.

Hygiene:
Change contaminated clothing, wash contaminated parts of the body.

Personal:
Wear tightly closing work clothes, safety boots, tightly fitting protective goggles,
respiratory mask, protective gloves, and head protection if necessary.

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3 General

PFD concerned

Process Flow Diagram concerned: Function Unit No.

PID concerned

Process and Instrumentation Diagrams concerned: Drawing No.


P&I-Diagram CFB-reactor Unit 1 A.23001-1-34100-VPI-DLE-5361
P&I-Diagram HP Water System Unit 1 A.23001-1-34100-VPI-DLE-8210

Technical Documentation concerned

Function Unit Function Unit No.


Technical Documentation Water Injection System Unit 1 TD/17.01

Arrangement Drawings

Drawing Title: Drawing No.


Control Unit with Spillback Nozzle Lance
Spillback Nozzle Lance with Parts List AV-800.117.82.00.00.0 A.23001-1-05330-MGD-LUE-0003

Accessories DN40 with Parts List AV-9ET.084.40.XY.08.0 A.23001-1-05330-MGD-LUE-0004

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4 Description

4.1 Task of the system

The water flow rate as required by the process is injected into the CFB-reactor with the
corresponding droplet size and spray angle with spillback nozzle lances.

4.2 Main components

The function unit spillback nozzle lance A.23001-1-05330-MGD-LUE-0003


(800.117.82.00.00.0) consists out of the main components:
- 1x spillback nozzle 261.036.1Y.78.00.Z
- Spillback nozzle lance 8F2.007.81.00.00.0
- Accessories DN40 A.23001-1-05330-MGD-LUE-0004
(9ET.084.40.0B.08.0)

The following components are not included in the scope of supply and are selected and
provided by the operating company:
- Mounting tube for installation in the CFB-reactor
- Blank lid/blank flange for sealing flange openings
- Screw connections for mounting the accessory on the floor
- Padlocks for locking the ball valves.

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4.2.1 Nozzle lance

C
A B

Legend
No. Designation
A Operating media connections (for connection of the accessories)
B Mounting flange with shifting device (for connection to the CFB-reactor)
C Protection tube
D Nozzle

NOTICE
Damage to property from incorrect handling
The atomisation quality depends to a great extent on the surface quality of the
nozzle, particularly on the outlet geometry (outlet surfaces and edges of the
nozzle). Incorrect handling can damage the outlet geometry of the nozzle. The
required atomisation quality is no ensured.
→ Handle nozzle lances and nozzles with care.
→ Protect the nozzles and the connections against damage and soiling.
→ Lay down or support the nozzle lance so that the nozzle does not touch the
floor.
→ Only use suitable tools.

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4.2.1.1 Mounting flange

The nozzle lance is provided with a mounting flange for installation in the CFB-reactor. A
corresponding mating flange (mounting tube) is welded into the CFB-reactor.

Mounting flange with shifting device on the nozzle lance

Legend
No. Designation
1 Pipe clamp with screw connections
2 Mounting flange
3 Guide pipe

The mounting flange can be shifted. Loosen the screw connections to release the pipe
clamp. Tighten the screw connections to fasten the pipe clamp.

4.2.1.2 Connections for operating media

The connections for operating media on the nozzle lance are implemented as follows:

1 2

Operating media connections at the nozzle lance

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Legend
No. Designation
1 Back flow (water) – quick-release coupling (socket)
2 Feed flow (water) – quick-release coupling (plug)

The quick-release coupling halves are assembled mirror-inverted (back flow – socket,
feed flow – plug) to prevent the feed flow and the back flow connections being mistakenly
swapped over.

4.2.1.3 Nozzle

Spillback nozzle

Legend
No. Designation
1 Housing
2 Sealing ring
3 Mouth piece
4 Swirl insert
5 Sealing ring (grooved seal)

4.2.2 Water accessories

The water accessories consist of a supply and return line. The supply and return line are
connected by a gang valve assembly and a mounting plate.

Assemble the operating media accessories to the feed lines prior to initial start-up. Only
disassemble accessories when the system is isolated from all possible sources of supply
and fully depressurized.

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D
C

B
Water accessory: (feed flow and back flow)

Legend
No. Designation
A Supply line
B Return line
C Gang valve assembly
D Mounting plate

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4.2.2.1 Supply line

The supply line supplies the nozzle lance with water.

5
4

2
1

Water accessory: Supply line

Legend
No. Designation
1 Weld-on union with special coupling (for connection to the supply line)
2 Connecting pipe
3 Strainer
4 High pressure hose
5 Quick release coupling socket (for connection to the nozzle lance)

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4.2.2.2 Return line

Part of the water is extracted from the nozzle lance through the return line.

4
3

Water accessories: Return line

Legend
No. Designation
1 Weld-on union with special coupling (for connection to the supply line)
2 Connecting pipe
3 Non-return valve
4 High pressure hose
5 Quick-release coupling plug (for connection to the nozzle lance)

4.3 Standards and guidelines

The following points are particularly to be observed in addition to the following operation
manual and the operating instruction for the accessory aggregates of the flue gas/incine-
ration plant:
- the general regulations and ordinances for operating the flue gas cleaning unit;
- the general accident prevention regulations
- the Health and Safety Regulations

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4.4 Operation description

The spillback nozzle lances are atomizing the water as a fine hollow cone with an outlet
angle of 90°.

The flow rate of the atomized water rate is controlled by a regulating valve
(11HTQ14AA001/11HTQ14AA002– see operation manual A.23001-1-05330-MOM-LUE-
0001 for the valve skid unit) in the common back flow line. Maximum injection occurs
when the return line is closed. Minimum injection occurs when the return line is opened.

The injected water flow rate is adjusted to the process requirements by opening respec-
tively closing the regulating valve 11HTQ14AA001/11HTQ14AA002 in the return line.

The feed flow pressure in the supply line in front of the spillback nozzle lance remains
always constant.

The turn down ratio is 10:1 (max.: min. flow rate with no change of number of nozzles)
maintaining a constant fine atomization over the full range.

4.5 Function of important equipment

4.5.1 Dirt trap

The strainer (feed flow line) stops all impurities bigger than the mesh size and thus
prevents the nozzles becoming blocked.

KKS-No.:

11HTQ13AT001
11HTQ13AT002
11HTQ13AT003
11HTQ13AT004
11HTQ13AT005

4.5.2 Gang valve assembly

If necessary, use the gang valve assembly to disconnect the nozzle lance (feed flow and
back flow simultaneously) from the supply line.

Open and close the gang valve assembly by rotating the hand lever 90°. Both positions
are constrained by a limit stop.

The gang valve assembly can be locked in both end positions.

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Position of the hand lever: gang valve assembly open (left), closed (right)

KKS-No.:

11HTQ13AA521, 11HTQ14AA521
11HTQ13AA522, 11HTQ14AA522
11HTQ13AA523, 11HTQ14AA523
11HTQ13AA524, 11HTQ14AA524
11HTQ13AA525, 11HTQ14AA525

4.5.3 Non-return valve

The non-return valve (return flow line) prevents liquid from being sprayed into the CFB-
reactor as a solid jet if the supply line is blocked.

KKS-No.:

11HTQ14AA701
11HTQ14AA702
11HTQ14AA703
11HTQ14AA704
11HTQ14AA705

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4.6 Technical data

4.6.1 Technical principles Lechler spillback nozzles

Lechler spillback nozzles are single-element nozzles, which operate on the principle of
pressurised atomization. They are designed to provide a turn down ratio within a range up
to 10:1, within which the volume of atomized liquid can be adjusted indefinitely. A resulting
droplet spectrum of virtually uniform fineness is achieved over the entire adjustment
range.

Lechler spillback nozzles atomise liquids in the form of a hollow cone typically with a spray
angle of 90° (e.g. 60°). Other angles and adjustment ratios are however available.

Lechler spillback nozzles permit the volume of atomized liquid to be matched to the re-
quirements of the particular process concerned. This is accomplished by means of a
return flow system where a volume of liquid is returned from the nozzle back through a
"spillback" line, before it can be atomized. The maximum atomized volume is obtained
when the spillback line is closed.

The ratio of atomized liquid to returned liquid is determined by the pressure in the spill-
back orifice in the swirl chamber. A control valve in the spillback line can be opened or
closed to vary the volume of liquid returned and, therefore, the volume of liquid atomized.

Irrespective of the atomized volume, the liquid is delivered to the nozzle at a constant
pressure via the supply tube (the outer tube of the lance). Inside the swirl disc, a propor-
tion of the linear pressure is transformed into centrifugal force, causing a certain amount
of the swirling liquid to be expelled from the nozzle through the mouth piece. A further
reduction in pressure, produced by the constriction in the cross-section of the mouth
piece, results in a corresponding increase in velocity and fine atomization of the liquid.

3 4 5

1
2
1

6
Operating principle of a spillback nozzle

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Legend
Item
1 Feed flow
2 Back flow
3 Swirl insert
4 Mixing chamber
5 Mouth piece
6 Back flow borehole

4.6.2 Design of Lechler nozzle lances

The design of the nozzle lance is matched to the nozzle used and to the local or process-
related features. The nominal diameters of the supply and return lines are based on the
nozzle rating.

In addition, the following points are decisive for the design of the nozzle lances:
- Operating temperature of the gas flow: Material selection, protection tube
- Corrosive properties of the gas flow: Material selection
- Abrasive substances in the gas flow: Protection tube
- Spraying direction of the nozzle lances: Continuous/counter current, angle below
which there is an injection into the gas flow
- Implementation of the operating media connections
- Dimension of the duct: Length of the nozzle lance
- Design of the connecting flange on the duct

The nozzle lances can be made from any metallic materials. They are manufactured
according to the latest manufacturing methods and are therefore always state-of-the-art.

The design of the nozzle lances ensures that they are extremely maintenance friendly and
that e.g. nozzles can be replaced without any subsequent modification of the lances.

To achieve an economically adapted lifetime, the solids content in the liquid should be
reduced to a minimum. Abrasive components, such as sand, quartz particles, etc., should
be obstructed by the filters upstream of the nozzle. We recommend using corresponding
filters.

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4.6.3 General information on Lechler nozzle lances

Lechler spillback nozzle lances can be constructed of any type of metal. They are made in
accordance with the latest manufacturing processes, thus ensuring compliance with the
latest state of the art.

Lances are designed to ensure exceptional ease of maintenance and to permit e.g.
spillback nozzles to be exchanged with no additional conversion work on the lance itself.

In order to minimise wear, the proportion of solids in the liquid should be reduced to a
minimum. Abrasive substances such as sand, particles of quartz, etc. should be removed
by means of a filter upstream of the nozzles. The mesh size should be not smaller than
25% of the narrowest cross section of the nozzle (see chapter 4.6.8.1 Single nozzle).

Damage resulting from wear in nozzles and lances is not covered by the terms of the
Lechler GmbH guarantee.

The spillback nozzle lance 800.117.82.00.00.0 (A.23001-1-05330-MGD-LUE-0003) is


designed for the following pressures:

Feed Flow: PN40


Back Flow: PN40

4.6.4 Water quality

NOTICE
If the water quality is poor or there are inadequate filters, the nozzle may
become blocked or large drips may form. This may result in unwanted operating
conditions and/or damage to the system. The solid content in the liquid must be
reduced to a minimum.
→ Use suitable filters the mesh size must not be selected larger than 25% of
the narrowest cross-section of the nozzle.

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Water quality

Chloride content max. 60 mg/l


Corrosive components (suitable for max. 450 mg/l
stainless steel)
pH value 6.0-8.0
Solids (equivalent ball diameter) < approx. 25% of the narrowest nozzle cross-section
Solid content < approx. 30 mg/l
Water hardness 80 mg CaO/l = 143 mg CaCO3/l
8 °dH
10 °e
14 °fH

4.6.5 Critical temperatures of the parts exposed to high temperatures

The maximum continuous operating temperature for the nozzle and the nozzle lance
depends to a great extent on the material used and the mode of operation.

The material of the nozzle lance exposed to high temperatures is made entirely from
stainless steel 1.4404 or a material of a comparable quality. The material 1.4404 has a
temperature resistance in air of 550°C.

NOTICE
If the nozzle lance is exposed to a temperature above 450°C (1.4404) over an
extended period of time, it may result in structural transformations within the
material. The corrosive resistance and mechanical stability will be permanently
impaired.

NOTICE
Always pay attention to the respective operating pressure and mechanical load
of the nozzle lance for the maximum permissible temperature. The permissible
tensile strength of the material and thus the compressive and mechanical
strength of the component decreases as the temperature increases.

At the maximum permitted operating pressure for the feed flow PN40 and back flow PN40
(4.6.8.2 Nozzle lance), the temperature T=400°C (1.4404) must not be exceeded. These
values are based on a creep strength Rm/10000.

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4.6.6 Nozzle parts and materials – data sheet 261.036.1Y.78.00.Z

No. Designation Product number Material


5 Sealing ring (ø33xø44x2) 095.015.71.04.41.0 Cu-ISOPLAN750
4 Sealing ring 095.015.1Y.05.07.0 1.4404
3 Swirl insert 261.036.Q9.78.06.0 1.4404 surface hardened
2 Orifice 261.036.4H.78.02.1 Carbide KR16
1 Housing 260.966.1Y.78.01.0 1.4404

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4.6.7 Pressure/flow rate diagram 261.036.1Y.78.00.Z

P(1) = 40
250.0

P(1) = 35

P(1) = 30

200.0 P(1) = 25

P(1) = 20

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4.6.8 Load cases and design data

4.6.8.1 Single nozzle

General data

Product number 261.036.1Y.78.00.Z


Nozzle type Spillback nozzle
Type RS6
Spray character Hollow cone
Spray angle approx. 90°
Turn down ratio 10 : 1
Narrowest cross-section ø 5.9 mm
Weight approx. 0.95 kg
Dimensions ø 65 x 75 mm
Feed flow connection G 1½" ISO228
Back flow connection G ¾" ISO228
Tools required Hook spanner with pin (cap ø 40-42 mm, pin ø 4 mm)
Open-ended spanner 55 AF

Performance data

Back flow closed 158.7 l/min ± 10% at 35 bar(g)


Back flow open 15.8 l/min ± 10% at 35 bar(g)

Projected operating point

Max. per nozzle 157.9 l/min ± 10% at 35 bar(g)


Min. per nozzle 23.4 l/min ± 10% at 35 bar(g)

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4.6.8.2 Nozzle lance

General data

Product number 800.117.82.00.00.0


Type Spillback nozzle lance
Material 1.4404
Mounting flange 8" ANSI 150lb/sq. in.
Feed flow connection G 1½" ISO228
Back flow connection G 1½" ISO228
Total length approx. 2128 mm
Weight without accessories 46.5 kg
Accessory with support 35 kg

Design data

Max. permitted operating pressure

Feed flow PN40


Back flow PN40

Max. permitted operating temperature

Nozzle 400°C
Lance 400°C
Protection tube 400°C

4.6.8.3 Complete installation

Injected flow rate 4 nozzle lances (4x 800.117.82.00.00.0 (A.23001-1-05330-MGD-LUE-0003))

Back flow closed 37.6 m3/h ± 10% at 35 bar(g)


Back flow open 3.9 m3/h ± 10% at 35 bar(g)

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4.6.9 Main equipment data

4.6.9.1 Dirt trap

KKS-No.:

11HTQ13AT001
11HTQ13AT002
11HTQ13AT003
11HTQ13AT004
11HTQ13AT005

Design: Housing - Y-Form

Connection: G 1½” ISO 228

Mesh size: 0,6 mm

Material: Housing – 1.4408;


Basket – 1.4401

4.6.9.2 Non-return valve

KKS-No.:

11HTQ14AA701
11HTQ14AA702
11HTQ14AA703
11HTQ14AA704
11HTQ14AA705

Connection: G 1½”

Material: 1.4571

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4.6.10 Classifying of pressure equipment according to directive 97/23/EG (PED)

Customer Doosan Lentjes GmbH


Project no. 62-13-132
Customer order no.: L83/1035539
Object Spillback Nozzle Lance
Product number 800.117.82.00.00.0

----------------------------------------------------------------------------------------------------------------------

Max. permitted pressure PS > 0.5 bar g yes


Exclusion from application field as per Art. 1 (3) (PED) no

Medium: Liquid (water)


Fluid group according to Art. 9(2) PED: Fluid group 2
Type of pressure equipment: Piping
Conformity assessment procedure according to Appendix II PED: Fig. 9

Pos. Designation DN PN Lechler drawing Max. Max. Classification as


allowable allowable per diagram 9
operating - operating PED
pressure temperature
1 Supply pipe ≤ 40 40 8F2.007.81.00.00.0 40 bar(g) 60°C No category
2 Return pipe ≤ 40 40 8F2.007.81.00.00.0 40 bar(g) 60°C No category
Enclosure: Fig. 9, Appendix II for the PED with entry

The spillback nozzle lance described above falls under Article 3 (3) of the PED on account
of the specified operating conditions and must not be assigned the CE label.

According to Article 3 (3) it must be designed and manufactured according to good


engineering practice.

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Spillback Nozzle Lances

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Operation and Maintenance Manual
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Spillback Nozzle Lances

5 Operation Instruction

5.1 Installation

5.1.1 Safety information for installation

5.1.1.1 Securing against unauthorised start-up

WARNING
Danger of death from unauthorised start-up
Parts and dangerous operating media may be released in an uncontrolled man-
ner in case of unauthorised start-up of the injection system during installation
work presents. There is a risk of injury or even death.
→ Ensure that nobody can be injured due to unauthorised start-up of the
injection system.
→ Seal off openings using suitable blank flanges.
→ Position safety signs: "Installation work. Do not open!"

5.1.1.2 Excess pressure in the duct

WARNING
Risk of severe burns from hot gas
Excess pressure in the duct can allow hot, dust-laden gas to escape out of
openings (mounting flange, media connections) in this duct. There is a risk of
injury or even death.
→ Work with the utmost care and attention to detail. Use suitable protective
equipment as specified.
→ Protect your face. Never look directly into the mounting tube. Never stand
directly in front of the opening.
→ After removing the blank flange, immediately insert the nozzle lance into the
mounting tube.
→ If necessary, seal off openings using suitable blank flanges.

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Operation and Maintenance Manual
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5.1.1.3 Incorrect installation and initial start-up

WARNING
Risk of injury from incorrect installation
Incorrect installation may result in serious injury or even death. Furthermore, this
could result in considerable damage to property.
→ Only allow work to be performed by specially trained staff (see 2.4 Staff
qualifications).
→ Work must be carried out by at least two people.
→ Ensure there is sufficient room to perform assembly.
→ Only use lifting equipment and load suspension devices with sufficient load
carrying capacity. Use suitable attachment points. Move nozzle lances as
close as possible to the floor.
→ Ensure that the assembly site is kept orderly. Any components and tools
which are lying around represent potential hazards.
→ Use suitable connecting elements (screw connections, seals etc.). The
material used must be suitable for the operating medium, the design
pressure and the design temperature.
→ Assemble the components correctly. Tighten screw connections evenly in a
criss-cross pattern using a torque wrench: The tightening torque must
correspond to the type, sizing and material of the screw connections and to
the required pressure stage.
→ Secure the components so that they do not fall down or topple over.
→ Before initial start-up ensure that all installation work is performed and
concluded properly.
→ Ensure that all connections are tight after initial start-up and starting up
again.
→ Check the tightening torques of the screw connections and the nozzle after
initial start-up. Only tighten the screw connections in a cooled down and
depressurised state.

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Operation and Maintenance Manual
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5.1.2 Initial installation

Perform a trial installation in advance. Then disassemble the nozzle lances. This prevents
the nozzle lances from being damaged whilst performing other work in the CFB-reactor.
Only install the nozzle lance in the CFB-reactor again shortly before start-up.

Prerequisite:
 Injection system is depressurised and has cooled down.
 Use suitable protective equipment: flame-resistant protective clothing, heat-resistant
protective gloves, protective helmet, safety goggles, breathing equipment, safety
shoes.

Carry out the following steps:


1) Check the installation length of the nozzle lance. See 5.1.3 Adjusting the installation
length of the spillback nozzle lance.
2) Install the nozzle lance. See 5.1.4 Installing the spillback nozzle lance.
3) Assemble the accessory on the supply line. See 5.1.5 Assembling the water
accessories at the supply lines.
4) Connect the accessory to the nozzle lance. See 5.1.6 Connecting the water
accessories to the nozzle lance.
5) Perform preparations for initial start-up. See 5.2 Preparation for start-up.

5.1.3 Adjusting the installation length of the spillback nozzle lance

By setting the correct installation length it is ensured that the spillback nozzles are in the
correct position after installing the nozzle lances in the CFB-reactor.

The shifting device is mounted as per the nozzle lance drawing upon delivery. Check the
installation length prior to installing the nozzle lances. Adjust the installation length if the
measured value deviates from the specification.

5.1.3.1 Checking the installation length

Check the installation length and the alignment of the connections for operating media as
per the nozzle lance drawing.

This requires:
 A tape measure
 Nozzle lance drawing A.23001-1-05330-MGD-LUE-0003 (800.117.82.00.00.0).
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Spillback Nozzle Lances

Carry out the following steps:


1) Measure length X.
- X = 1500 mm

2) Check the alignment of the connections for operating media.


3) If the measured length deviates from the specification or the connections are not
correctly aligned, adjust the installation length of the nozzle lance.

5.1.3.2 Adjusting the installation length

Ensure the correct alignment of the connections for operating media.

This requires:
 A tape measure
 2x open-ended spanner (19 AF)
 Nozzle lance drawing A.23001-1-05330-MGD-LUE-0003 (800.117.82.00.00.0).

Carry out the following steps:


1) Loosen the pipe clamp.

2) Adjust the shifting device to set length X:


- X = 1500 mm

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Operation and Maintenance Manual
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3) Align the operating media connections according to the drawing.


4) Tighten the pipe clamp.
5) Measure length X once more.

TIP
Secure the guide sleeve and the nozzle lance by a welding spot after the final spraying
position for the spillback nozzle lance has been found. Thereby it should be avoided that
the installation length is changed afterwards.

5.1.4 Installing the spillback nozzle lance

This chapter describes how to install the nozzle lance in the CFB-reactor. Assembly
personnel are exposed to an increased risk during assembly. Be particularly careful and
cautious.

WARNING
Risk of severe burns from hot gas
Excess pressure in the duct can allow hot, dust-laden gas to escape out of
openings (mounting flange, media connections) from this duct. There is a risk of
injury or even death.

→ Work with the utmost care and attention to detail. Use suitable protective
equipment as specified.
→ Protect your face. Never look directly into the mounting tube. Never stand
directly in front of the opening.
→ After removing the blank flange, immediately insert the nozzle lance into the
connecting piece.
→ If necessary, seal off openings using suitable blank flanges.

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Operation and Maintenance Manual
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Spillback Nozzle Lances

WARNING
Danger of death from unauthorised start-up
Unauthorised start-up of the nozzle lance during installation work presents the
risk that parts and dangerous operating media (under pressure) might be
released in an uncontrolled manner. There is a risk of injury or even death.
→ Secure the shut off valve against being opened unintentionally.
→ Seal off openings using suitable blank flanges.
→ Position safety signs: "Installation work. Do not open!"

NOTICE
Damage to the nozzle due to incorrect handling
Incorrect handling may damage the outlet surfaces or separation edges of the
nozzle.
→ Carefully insert the nozzle lance into the mounting tube. Make sure the
nozzle does not collide with other components.

Prerequisite:
 The following steps must be carried out by at least two people (trained and qualified
staff).
 Use of suitable protective equipment: flame-resistant protective clothing, heat-resistant
protective gloves, safety goggles, breathing equipment, safety helmet, safety shoes.
 Mounting tube has been welded into the CFB-reactor correctly. Position see drawing
A.23001-0-33100-UGD-DLE-0002.
 The nozzle lance installation length has been adjusted.
 All components are in good working order.

This requires:
 Suitable facilities like e.g. a lifting block for safeguarding
 2x open-ended spanner (30 AF)
 1x torque wrench with open-ended spanner attachment (30 AF)
 8x hex bolt M20x90-A2 respectively with hex nut and washer
 1x flat gasket for mounting flange.
 Nozzle lance drawing A.23001-1-05330-MGD-LUE-0003 (800.117.82.00.00.0).

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Carry out the following steps:


1) Slide the flat gasket onto the nozzle lance from the direction of the nozzle.

2) Remove the blank flange from the mounting tube. Then immediately insert the nozzle
lance into the mounting tube.
→ Position the lance pipe in the mounting tube. Make sure the nozzle does not collide
with other components.

3) Align the operating media connections according to the drawing.


4) Position the flat gasket in the middle of the sealing surface of the mounting tube.

5) Pre-assemble the bolts in the flange.


→ Push the bolts through the holes from the direction of the operating media
connections.
→ Place a washer underneath each nut.

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6) Slightly tighten each nut.


7) Correct the position of the flat gasket.
8) Uniformly tighten the screw connections crosswise, using a torque wrench.

TIP
Use heat-resistant silicone to bond the flat gasket to the mounting tube in order to
facilitate nozzle lance assembly and to prevent the flat gasket from being sucked into the
duct.

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5.1.5 Assembling the water accessories at the supply lines

Special pipe couplings are provided on the water accessory for connection to the supply
lines. Prior to assembling the accessories, check the length of the supply tubes and adapt
them accordingly. It’s also possible to adapt the length of the connecting pipes of the
accessories. Spare cutting rings are provided therefore.

1
2
3

Legend
No. Designation
1 Gang valve assembly
2 Connecting pipe
3 Support
4 Coupling
5 Supply pipe

Prerequisite:
 The system is shut down and fully depressurised.
 Ball valves for emptying the supply lines are available in the system (opposite the
connections for the rising pipe).

This requires:
 4x hex bolt M10 (length according to the floor thickness), respectively with hex nut and
washer.
 2x open-ended spanner (16 AF)
 Screw connections for mounting the accessory on the floor
 Welding equipment
 Drawing A.23001-1-05330-MGD-LUE-0003 (800.117.82.00.00.0).
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Operation and Maintenance Manual
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Spillback Nozzle Lances

WARNING
Danger of death from unauthorised start-up
Unauthorised start-up of the injection system during installation work presents
the risk that parts and dangerous operating media (under pressure) might be
released in an uncontrolled manner. There is a risk of injury or even death.
→ Before you start the work, ensure that the injection system is shut down,
depressurised, and has cooled down.
→ Position safety signs: "Installation work. Do not open!"
→ Seal off openings using suitable blank flanges.

NOTICE
Damage to property due to incorrect assembly
Incorrect assembly can result in damage to the nozzle lance and to the
system.
→ Pay attention to the correct size of the boreholes. A high drop in pressure -
may occur if the hole diameter in the supply line is smaller than the
diameter of the weld-on union.
→ Assemble the accessory so that no stresses are applied. Pay attention to
the correct position of the weld-on unions and the alignment of the
connecting tubes. Adjust the length of the connecting tubes.
→ Lay the high pressure hoses so that they are free of kinks.
→ Ensure that you don't switch the supply and return lines during assembly.
The direction of flow is marked with an arrow on the operating media
connections. A solid jet is generated when spraying if the supply line is
accidentally connected to the return line connection.

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Carry out the following steps:


1) Assemble the gang valve assembly to the support (815.080.00.1C.03.0).

2) Carry out a trial installation with the lance accessory and the support. Adapt the length
of the existing ø48.3mm tubes for the feed and return line if a stress free assembly of
the lance accessory with the support shouldn’t be possible.
a) Put the lance accessory with the couplings on the existing ø48.3mm tubes for the
feed and return line on-site until they hit the end of the cut out inside the coupling.

b) Position the support on the floor. Check the base plate position of the support. The
support should touch the floor with the base plate at the same time when the coup-
lings of the accessories hit the end of the cut out.
c) Reduce the length of the existing ø48,3mm tubes for the feed and return line by
cutting if required.
3) Assemble the accessory.

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4) Weld the accessory with the couplings to the ø48.3mm tubes for the feed and return
line with a fillet weld (socket weld).

5) Assemble the support on the floor.


→ Before start-up, flush the ring mains with sufficient water and then clean the
strainer (supply line).

5.1.6 Connecting the water accessories to the nozzle lance

Damaged high pressure hoses, gaskets or other connecting components must be


replaced immediately to avoid any risk for the personnel and/or the plant.

When connecting the high pressure hoses, take care to ensure that the supply and return
lines are not swapped over among each other. It has to be ensured that the high pressure
hose do not bend during assembling.

Clean the sealing surfaces every time you assemble a unit.

Prerequisite:
 The nozzle lance is installed properly.
 Accessories have been assembled at the supply lines and flushed sufficiently.

This requires:
 Vaseline or mineral-based grease for lubricating the coupling gaskets.

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WARNING
Risk of severe burns from hot gas
Excess pressure in the duct can allow hot, dust-laden gas to escape out of
openings (mounting flange, media connections) in this duct. There is a risk of
injury or even death.
→ Work with the utmost care and attention to detail. Use suitable protective
equipment as specified.
→ Protect your face. Never look directly into the mounting tube. Never stand
directly in front of the opening.
→ Connect the high pressure hose to the nozzle lance immediately after
removing the blank flange.

WARNING
Danger of death from unauthorised start-up
Unauthorised opening of the shut off valve during installation work presents the
risk that dangerous operating media (under pressure) might be released in an
uncontrolled manner. Loose high pressure hoses will move in an uncontrolled
manner when under pressure. There is a risk of injury or even death.
→ Ensure that nobody can be injured due to unauthorised opening of the shut
off valve.
→ Position safety signs: "Installation work. Do not open!"

NOTICE
Damage to the nozzle lance and the system due to incorrect connection
of the water accessories
A solid jet is generated when spraying if the return line is unintentionally
connected to the supply line connection. The required spray quality is no
longer guaranteed.
→ Ensure that the supply and return lines aren't switched during assembly.
The direction of flow is marked with an arrow on the operating media
connections.
→ Assemble the high pressure hoses so that they are free of kinks.

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Operation and Maintenance Manual
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Carry out the following steps:


1) Water accessory - connect the feed flow at the nozzle lance.

d) Open the clamping lever and the coupling clamp (plug).

CAUTION
Risk of injury due to incorrect handling of the quick-release couplings
→ Make sure the quick-release coupling cannot trap or injure your hands
when moving the clamping lever.

e) Clean the coupling gasket and lightly grease with Vaseline.

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f) Insert the coupling connector as far as possible into the coupling sleeve (socket).

g) Close the coupling clamp and the clamping lever.

h) Check whether the quick release coupling is assembled correctly. The high
pressure hose can’t get pulled out when the coupling clamp is closed.
2) Water accessory - connect the back flow at the nozzle lance.

a) Open the clamping lever and the coupling clamp (in the accessories).

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b) Clean the coupling gasket and lightly grease with Vaseline.

c) Insert the coupling connector as far as possible into the coupling sleeve.

d) Close the coupling clamp and the clamping lever.

e) Check whether the quick release coupling is assembled correctly. The high
pressure hose can’t get pulled out when the coupling clamp is closed.

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5.1.7 Nozzle lance position

HINWEIS
Damage to the plant and/or the lance
If the nozzle lances are mounted in an incorrect position or direction, the plant
and/or lance may be damaged.
→ Take care that the spillback nozzle lances are mounted in the correct
position and that they are spraying in the correct direction.

The correct position and direction of the nozzle lances see drawing
A.23001-0-33100-UGD-DLE-0002.

5.1.8 Electrical connection

Not applicable.

5.2 Preparation for start-up

5.2.1 Flushing the piping with water

Before commissioning the water spray system first time all piping before the spillback
nozzle lances must be thoroughly flushed with water.

5.2.2 Filling the supply line with water

During initial start-up or after stoppages, (re)fill the supply line – feed flow (from the pump
to the quick-release coupling in the feed flow accessories) with water. The nozzle lance
can be put into operation if the test criteria have been complied with and the supply line is
fully filled with water.

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Prerequisite:
 Test criteria have been complied with.
 Shut-off valves in the supply lines are open.

This requires:
 Manual pump
 Suitable device for securing the high pressure hose.

WARNING
Risk of injury due to pressurized medium
The pressure from the pump is too high to fill the supply line. Water under high
pressure may escape from the high pressure hose. There is a risk of serious
injury and death.
Disassembled high pressure hose under high pressure will move in an uncon-
trolled and random manner. There is a risk of serious injury and death.
→ Use a hand pump to fill the supply line or take water from the water
network.
→ Point the end of the hose which isn't connected in a safe direction and
safely secure the high pressure hose.
→ Carry out the procedure slowly.
→ Do not look directly into the opening of the high pressure hose.
→ Never stand directly in front of the opening of the high pressure hose.

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Carry out the following steps:


1) Open the gang valve assembly on the water accessory.

2) Quick-release coupling in the water accessories - open feed flow. Ensure the quick-
release coupling is facing in a safe direction.
3) Fill the supply line (from the pump to the quick-release coupling) with water.
→ The supply line is full when water leaks from the quick-release coupling.
4) Close the gang valve assembly on the water accessory.

5) Water accessory - re-connect the feed flow to the nozzle lance.

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5.2.3 Functional Tests

A spray test with the spillback nozzle lances 11HTQ20BN001, 11HTQ20BN002,


11HTQ20BN003, 11HTQ20BN004, 11HTQ20BN005 outside the CFB-reactor should be
carried out regularly according to fixed intervals.

5.3 Conditions for start-up

5.3.1 Check criteria before commissioning

Check the following criteria before commissioning and operating the nozzle lance:
- Has the nozzle lance been installed in the CFB-reactor correctly (installation
length, spraying direction, screw connections)?
- Have the operating media accessories been assembled correctly (feed flow and
back flow connected properly)? Has the strainer in the water accessories (supply
line) been cleaned?
- Have the supply lines been assembled and flushed correctly, as well as checked
for leaks?
- Has the nozzle been assembled and flushed correctly, as well as checked for
leaks?
- Have all the connections (flange, welded and screw connections) been checked for
leaks?
- Are all the components in efficient working order?

The nozzle lance may only be put into operation if all the relevant test criteria have been
complied with.

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5.3.2 Valve position list

5.3.2.1 Valve position before start-up

This list describes the positions of valves before start-up (plant / system out of operation).
Before start-up it has to be checked thoroughly by the operator that all valves – including
manual valves – are in “before start up”-position according to the following list:

position before
KKS-No P&ID Number start-up Manual automatic
11HTQ13AA502 A.23001-1-34100-VPI-DLE-8210 closed
11HTQ13AA506 A.23001-1-34100-VPI-DLE-8210 closed
11HTQ13AA521 A.23001-1-34100-VPI-DLE-8210 opened
11HTQ13AA522 A.23001-1-34100-VPI-DLE-8210 opened
11HTQ13AA523 A.23001-1-34100-VPI-DLE-8210 opened
11HTQ13AA524 A.23001-1-34100-VPI-DLE-8210 opened
11HTQ13AA525 A.23001-1-34100-VPI-DLE-8210 opened
11HTQ14AA501 A.23001-1-34100-VPI-DLE-8210 closed
11HTQ14AA508 A.23001-1-34100-VPI-DLE-8210 closed
11HTQ14AA521 A.23001-1-34100-VPI-DLE-8210 opened
11HTQ14AA522 A.23001-1-34100-VPI-DLE-8210 opened
11HTQ14AA523 A.23001-1-34100-VPI-DLE-8210 opened
11HTQ14AA524 A.23001-1-34100-VPI-DLE-8210 opened
11HTQ14AA525 A.23001-1-34100-VPI-DLE-8210 opened
11HTQ14AA701 A.23001-1-34100-VPI-DLE-8210 Check Valve
11HTQ14AA702 A.23001-1-34100-VPI-DLE-8210 Check Valve
11HTQ14AA703 A.23001-1-34100-VPI-DLE-8210 Check Valve
11HTQ14AA704 A.23001-1-34100-VPI-DLE-8210 Check Valve
11HTQ14AA705 A.23001-1-34100-VPI-DLE-8210 Check Valve

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5.3.2.2 Valve position during operation

This list describes the positions of valves during normal operation:

Valves
KKS-No. Position Comment
Operation

11HTQ13AA521 + open Only, if the lance 11HTQ20BN001


11HTQ14AA521 should be put into operation

11HTQ13AA522 + open Only, if the lance 11HTQ20BN002


11HTQ14AA522 should be put into operation

11HTQ13 AA523 + open Only, if the lance 11HTQ20BN003


11HTQ14AA523 should be put into operation

11HTQ13AA524 + open Only, if the lance 11HTQ20BN004


11HTQ14AA524 should be put into operation

11HTQ13AA525 + open Only, if the lance 11HTQ20BN005


11HTQ14AA525 should be put into operation

5.4 Putting the nozzle lance into operation

The nozzle lance may only be put into operation if all relevant test criteria have been
complied with. See chapter 5.3 Conditions for start-up.

Start up of the centrifugal pump (11HTQ11AP001, 11HTQ12AP001) – see the operation


manual for the valve skid unit (A.23001-1-05330-MOM-LUE-0001).

If non-atomized liquid enters the CFB-reactor it may cause the system to malfunction. Pay
attention to the correct sequence of steps.

NOTICE
Damage to the nozzle lance caused by pressure surges
Before start-up, ensure that the nozzle lance hasn't already heated up to such
an extent that the liquid to be atomized evaporates inside the nozzle lance.
Sudden evaporation of liquid will cause pressure surges and the nozzle lance
may be damaged.
→ If the nozzle lance is already very hot, allow it to cool down before putting it
into operation.

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Prerequisite:
 Test criteria have been complied with (5.3 Conditions for start-up).
 Supply line (feed flow) has been filled with water (5.2 Preparation for start-up).

Carry out the following steps:


1) Open the gang valve assembly on the water accessory.

→ If the system is in operation (other nozzle lances are spraying), the nozzle lance is in
operation.
→ If the system is to be put into operation, open all the gang valve assemblies and
continue with step two.
2) Fully open one control valve 11HTQ14AA001/11HTQ14AA002 in the back flow line in
the valve skid unit.
3) Start the pump 11HTQ11AP001/11HTQ12AP001 and adjust the water flow rate with
the control valve in the back flow line.

5.5 Operation

The water injected into the CFB-reactor with the spillback nozzle lances 11HTQ20BN001,
11HTQ20BN002, 11HTQ20BN003, 11HTQ20BN004 required by the process is adjusted
with the pneumatic actuated control valve 11HTQ14AA001/11HTQ14AA002 - see the
operation manual for the valve skid unit (A.23001-1-05330-MOM-LUE-0001).

5.5.1 Control walkabout

The following points have to be checked during the control walkabout:


- Visual check of the tightness of the complete installation
- Visual check of the complete installation regarding corrosion or/and abrasion.

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5.5.2 Check schedule

The cycle for the control walkabouts should be carried out determined in accordance with
the operating method employed and experienced gained.

Function checks and maintenance activities for all components have to be done in accor-
dance with the specific O&M requirements of the supplier. Please check the related sec-
tion of the O&M Manual.

Completing these requirements the following controls have to be done additionally (see
chapter 8 Routine maintenance):
Daily activities:
- Visual check of the tightness
- Check pressure in front of the spillback nozzle lances

Weekly activities:
- Visual check of lance and nozzle regarding corrosion or/and abrasion
- Check of the strainer
- Spray test with spillback nozzle lance

Monthly activities:
- Check of the non-return valve
- The quick release couplings are to be lightly greased after being opened for
cleanings, and the O-rings if necessary.

5.5.3 How to react on alarms

Not applicable

5.6 Shut-down

This section describes decommissioning of the nozzle lance and how to dismantle it from
the CFB-reactor.

It is recommended to remove nozzle lances not required for the water injection from
exposure to the stream of hot gas immediately, in order to prevent damage from thermal
stress. This will prolong the life of the individual lances.

The operator is advised to purge the spillback nozzle lances with compressed air for a
certain period of time. This will prevent residual liquid from vaporising in the lance po-

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tentially resulting in the formation of deposits, which could break away and impair the
optimum atomization of the liquid when the lance is returned to service.

After the nozzle has been removed, the operator is advised to close the open aperture in
the CFB-reactor with a corresponding blanking flange.

5.6.1 Putting the nozzle lance out of operation

Carry out the following steps:


1) Close the gang valve assembly in the water accessories.

→ If the nozzle lance is disassembled for maintenance, proceed with section


5.6.2 Disconnect the water accessories.
→ If the nozzle lance is not required for operation but is left installed in the CFB-reactor,
blow the nozzle lance out with compressed air if possible.
→ If the nozzle lance is not required for operation and is disassembled from the CFB-
reactor, blow the nozzle lance out with compressed air if possible. Then proceed with
section 5.6.2 Disconnect the water accessories.

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5.6.2 Disconnect the water accessories

WARNUNG
Danger of death due to uncontrolled movement of parts and operating
media under high pressure
The water accessory is under high pressure during operation. Pressurised high
pressure hoses which have been disconnected will move in an uncontrolled
manner. Other parts may be ejected. Water under high pressure is ejected as
well. There is a risk of injury or even death.
→ Only disconnect the high pressure hose once it has been depressurised.
→ Lock the shut off valve out so it cannot be opened accidentally.
→ Apply warning signs, e.g. "Maintenance work. Do not open!"
→ Use suitable protective equipment as specified.

WARNING
Risk of severe burns from hot gas
If there is excess pressure in the duct, hot, dust-laden gas can escape when
opening the flange connection. There is a risk of injury or even death.
→ Use suitable protective equipment.
→ Protect your face. Do not look directly into the opening. Never stand directly
in front of the opening.
→ Close the open connection immediately with a suitable blank flange

Prerequisite:
 The nozzle lance is disconnected from the water supply (5.6.1 Putting the nozzle lance
out of operation).
 Water accessories are depressurized.

Carry out the following steps:


1) Water accessories - disassemble the back flow.

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a) Open the clamping lever and the coupling clamp (plug).

CAUTION
Risk of injury due to incorrect handling of the quick-release couplings
→ Hold the quick-release coupling so that you don't cannot trap or injure
your hands when moving the clamping lever

b) Remove the coupling connector from the coupling sleeve (socket).

2) Water accessories - disassemble the feed flow

a) Open the clamping lever and the coupling clamp (plug).

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b) Remove the coupling connector from the coupling sleeve.

5.7 Spillback nozzle lance removal

Assembly personnel are exposed to an increased risk during disassembly. Be particularly


careful and cautious.

Prerequisite:
 The following steps must be carried out by at least two people (trained and qualified
staff).
 Use of suitable protective equipment: flame-resistant protective clothing, heat-resistant
protective gloves, safety goggles, breathing equipment, safety helmet, safety shoes.
 The water accessory is disconnected from the nozzle lance (5.6.2 Disconnect the
water accessories).

This requires:
 2x open-ended spanner (AF 30) (for the screw connections on the mounting flange)
 Blank flange for the mounting tube.

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WARNING
Risk of severe burns from hot gas
If there is excess pressure in the duct, hot, dust-laden gas can escape when
opening the flange connection. There is a risk of injury or even death.
→ Use suitable protective equipment.
→ Protect your face. Do not look directly into the opening. Never stand directly
in front of the opening.
→ After un-installing the nozzle lance, immediately use a suitable blank flange
to close the mounting tube

WARNING
Risk of burns from hot surfaces
The nozzle lance becomes very hot in the hot gas flow. Contact with hot
surfaces is unavoidable when disassembling the nozzle lance. There is a risk of
burns.
→ Use suitable protective equipment as specified.

WARNUNG
Risk of injuries from hazardous liquids
→ If the nozzle lance is operated with aggressive, corrosive, hazardous or
environmentally unfriendly liquids, the nozzle lance liquid lines must also be
flushed through with water after being blown through with atomizing air
before being removed.

NOTICE
Damage to the nozzle due to incorrect handling
The quality of atomization depends heavily on the condition of the surfaces of
the nozzle, particularly the outlet geometry of the mouth piece. If the outlet
surfaces and/or breakaway edges of the spillback nozzle are damaged, the
requisite quality of atomization will no longer be assured.
→ Carefully remove the nozzle lance from the mounting tube. Make sure the
nozzle does not collide with other components.

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Carry out the following steps:


1) Loosen the screw connections on the mounting flange and remove all but two of the
screw connections.
2) Remove the last two screw connections and take the nozzle lance out of the mounting
tube immediately. Make sure the nozzle does not collide with other components.
→ Lance pipe is positioned in the mounting tube.

3) Close the mounting tube at once with the blank flange.


→ Clamp and support the nozzle lance in a suitable fixture for maintenance and let it cool
down.
→ If the nozzle lance isn't required, place the nozzle lance in a suitable location and let it
cool down.

5.8 Frost protection

Since the injection spray system is not constantly in operation, it must be ensured that the
water in the nozzle lances does not freeze at corresponding temperatures during in-opera-
tional times. For one thing, damages to the nozzle lances respectively component parts of
the accessories can occur, and for another, the water spray system is no longer operatio-
nally ready.

If necessary, the high pressure hoses for the feed and back flow have to be dismounted
(see 5.6 Shut-down) and drained when the injection spray system is not in operation.

Additional the sealing cap at the strainer (A.23001-1-05330-MGD-LUE-0004


(9ET.084.40.XY.08.0) – pos. 502) must be opened. This avoids the damaging of the filter
insert because of freezing.

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5.9 Storage when not in use

When not in use, the nozzle lance must be stored in the following way. Otherwise it may
be damaged.

The nozzle lance and the accessory must be stored as follows:


- Dry and dust-free
- Not exposed to aggressive media
- In a frost-free place
- Protected against the elements and mechanical damage (particularly the nozzles
and operating media connections).

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6 Troubleshooting

This chapter describes how to eliminate faults which may occur during operation.

→ Pay close attention to all relevant safety instructions!


→ It’s only allowed to carry out any kind of trouble shooting and inspection for
electrical components when they are isolated!

6.1 Operation during fault conditions

Five spillback nozzle lances 11HTQ20BN001, 11HTQ20BN002, 11HTQ20BN003,


11HTQ20BN004, 11HTQ20BN005 (drawing A.23001-1-05330-MGD-LUE-0003
(800.117.82.00.00.0)) are delivered by Lechler GmbH. Four lances are in operation and
one is for standby.

Isolate the feed flow and return flow lines of the faulty spillback nozzle lance by closing of
the gang valve assembly A.23001-1-05330-MGD-LUE-0004 – pos. 1
(9ET.084.40.XY.08.0) and dismantle the spillback nozzle lances from the CFB-reactor
according to the procedure described in chapter 5.7.

6.2 Preventive measures to avoid fault situations

The best method to avoid faults or keep their consequences at a minimum is to be very
attentive when monitoring the process on screen and to make regular inspection tours of
the equipment.

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6.3 Typical faults and suggested remedies

If the required atomization quality and thus the demanded process parameters (e.g. target
temperature with gas cooling, complete evaporation of the drips) are not achieved, it may
be due to the following reasons.

Fault Cause Remedy


Required process The necessary levels of media pressure Use a pressure gauge to check the
parameters are not are not provided (by the operator). pressure levels.
achieved. Check the position of the manual
shut-off valves.
The connections of the supply and Assemble the connections correctly.
return lines have been mistakenly
swapped over.
The connections of the supply and Replace defective parts.
return lines are defective. The required
pressure cannot be obtained.
A gang valve assembly has not been Check and correct the gang valve
opened fully. assembly.
A strainer is blocked. Clean and if necessary replace the
strainer.
Non-return valve is blocked. Clean and if necessary replace the
non-return valve.
The geometry of the nozzle orifice is Replace the orifice.
damaged.
Other system components or pipes are Check and correct.
defective or blocked.
Spray pattern isn't Swirl insert (nozzle) is blocked or Clean and if necessary replace the
uniform damaged. swirl insert.
Mouth piece (nozzle) is blocked or Clean and if necessary replace the
damaged. mouth piece.
Strainer is blocked or damaged. Clean and if necessary replace the
strainer.
the spray pattern Swirl insert is blocked or damaged. Clean and, if necessary, replace the
becomes entirely jet-like swirl insert.
Non-return valve is blocked or Clean and, if necessary, replace the
damaged. non-return valve.

If the fault cannot be rectified, please contact your Lechler GmbH representative.

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7 System stand still

Pay close attention to the safety points during inspection and maintenance work.

Regular maintenance is essential. Failures caused by inadequate or unsuitable


maintenance will lead to very high costs and long down time.

7.1 Short-term stoppages

A short time period of stoppage is understood to be an interruption for around max. 4


hours. During this time period, the plant must be maintained in an operational state.

The spillback nozzle lances are kept installed into the CFB-reactor.

7.2 Stoppages of up to 48 hours duration

If there is a longer stoppage of the water spray system than 4 hours it is recommended to
remove the spillback nozzle lances from the CFB-reactor (see chapter 5.7).

If the spillback nozzle lances are removed the mounting tubes have to be closed off with
corresponding blank flanges (not scope of supply of Lechler GmbH).

7.3 Stoppages of over 48 hours duration

Remove the spillback nozzle lances from the CFB-reactor and close off the mounting
tubes with corresponding blank flanges (not scope of supply of Lechler GmbH).

Drain the complete water spray system (see operation manual A.23001-1-05330-MOM-
LUE-0001 for the valve skid unit).

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8 Routine maintenance

This chapter describes the maintenance work required for optimal and fault-free operation
of the nozzle lances.

In order to ensure optimal and fault-free operation of the nozzle lances, the proper con-
dition of all lances installed in the CFB-reactor and the entire installation must be checked
at regular intervals. These checks include visual inspections and spray tests outside the
CFB-reactor. If necessary, further maintenance work must also be performed.

Replace damaged, worn parts immediately. Only use original spare parts. Contact
Lechler GmbH about possible repair work.

Maintenance work may only be performed by trained specialist staff.

8.1 Maintenance schedule

8.1.1 Adjust the maintenance intervals

The following maintenance intervals are recommendations and are intended as guidance.
The final maintenance intervals are to be determined by the operator. Experience during
the first few weeks following start-up, the operating mode and conditions on site are used
as criteria for determining these intervals. Carry out maintenance at more frequent inter-
vals in the first weeks after initial start-up.

If the process runs smoothly and you don't find any inadmissible abnormalities when
inspecting the nozzle lances, then the maintenance intervals can be extended accor-
dingly.

Possible procedure for determining the final intervals for maintenance activities outside of
the duct:
- 4-6 hours after initial start-up, remove all nozzle lances and inspect them for super-
ficial fouling and visible damage (especially the nozzles). If no inadmissible abnor-
malities are detected during the visual inspection:
- 2-7 days after initial start-up (daily), remove all nozzle lances and inspect them for
superficial fouling and visible damage (especially the nozzles). If no inadmissible
abnormalities are detected during the visual inspection:
- Remove the nozzle lances every 7 days, perform a visual inspection, spray test
and any required additional maintenance work.
Should you detect inadmissible abnormalities, check all the nozzle lances at each mainte-
nance interval until the process runs properly again.

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8.2 Safety information for maintenance

8.2.1 Danger from incorrect maintenance

WARNING
Risk of injury from incorrect maintenance
Incorrect maintenance may result in serious injury or even death. Furthermore,
this could result in considerable damage to property.
→ Only allow work to be performed by specially trained staff.
→ Work must be carried out by at least two people.
→ Always inform operating staff before carrying out maintenance.
→ Always use suitable protective equipment.
→ Only open locking devices when depressurised. Before starting work:
- Depressurise the system.
- Secure shut-off valves from being opened unintentionally.
- Allow heat-carrying lines to cool down.
- Check that the system is depressurised, if necessary by carefully
opening one of the connections.
- Position warning signs, e.g., "Maintenance work. Do not open!".
- Seal off openings using suitable blank flanges.
→ Do not exceed the maintenance intervals, adjust if necessary.

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8.2.2 Spray tests outside of the CFB-reactor

WARNING
Risk of injury from the uncontrolled movement of parts
Nozzle lances and high pressure hoses which are not properly secured can
become loose during the spray test. Loose nozzle lances and high pressure
hoses will move in an uncontrolled manner when under pressure. Furthermore,
parts could be propelled outwards. There is a risk of injury or even death.
→ Clamp the nozzle lances in a suitable fixture.
→ Prior to commencing the spray test, ensure that all the nozzles are properly
secured and that the high pressure hoses for water and compressed air are
connected correctly.
→ Only disconnect the high pressure hoses from the nozzle lances when the
former are depressurised.

WARNING
Risk of injury from the flow of liquid under high pressure
If the flow of liquid penetrates orifices at high pressure, this can result in serious
injuries. Moreover, touching the flow of liquid under high pressure or at high
temperature can result in serious injuries or even death.
→ Never direct the flow of liquid at persons.
→ Never hold your hand in the flow of liquid if the nozzle lance is being
operated at a high pressure or temperature.
→ Use suitable protective equipment as specified.

WARNING
Risk of injury from electric shock, chemical burns, poisoning
If the jet is directed towards live parts, acid baths or similar, this can result in
serious or even fatal injuries. There is a risk of poisoning when using media
which is hazardous to health.
→ Never direct the jet at sensitive system components such as live parts,
electrical devices, acid baths or similar.
→ Only use uncritical media, e.g., water and compressed air.

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WARNING
Risk of injury from swirled up parts
Parts which are hit by the high-pressure jet may be swirled up and injure indivi-
duals.
→ Use suitable protective equipment as specified.
→ Ensure that the operating media are conducted away safely.

WARNING
Risk of injury from noise
The spray test creates noise. At higher pressures in particular there is a risk of
hearing damage.
→ Use suitable ear protection.

NOTICE
Damage to the nozzle lance and the system due to incorrect assembly of
the accessories
Incorrect assembly of the couplings at the nozzle lance may result in the opera-
ting media accessories being connected incorrectly.
A solid jet is generated when spraying if the supply and the return line have
been mistakenly swapped over. The required spray quality is no longer guaran-
teed.
If the return line is unintentionally connected to the barrier air connection, ato-
mized medium is not supplied to the flow duct. Moreover, the nozzle lance may
be damaged, as the barrier air pipe has been designed for a lower pressure.
→ Make sure the operating media connections are not swapped over when
assembling the couplings.

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8.2.3 Maintenance schedule

Interval Component Task -See …

Visual inspection for damage, 8.3.1 Visual inspection


soiling, leaks
Weekly Nozzle lance Disassembling the nozzle lance 5.7 Spillback nozzle lance
removal
 Visual inspection 8.3.1 Visual inspection
 Clean, if necessary 8.3.2 Cleaning the nozzle
 Repair if necessary lance
 Replace, if necessary 8.3.3 Spray test
 Check the spray pattern
Nozzle  Visual inspection 8.3.5.2 Visual inspection
 Clean, if necessary 8.3.5.3 Clean the nozzle
 Replace, if necessary
Strainer  Check for soiling 8.3.7 Cleaning the strainer
 Clean strainer insert
 Replace, if necessary
Monthly Non-return valve  Check for leaks 8.3.6 Non-return valve
 Check correct functioning
 Clean, if necessary
 Replace, if necessary
Every 6 High pressure hoses  Check for leaks and visible 8.3.8 Inspecting the high
months damage pressure hoses
 Replace, if necessary

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8.3 Maintenance work

8.3.1 Visual inspection

The nozzle lances must be checked for superficial soiling, leaks and visible damage. All
deposits and damage to the nozzle lances which may have a negative effect on safety
and spray quality are to be regarded as critical. If necessary, the nozzle lances and/or
nozzles are to be cleaned or replaced.

Any soiling on the nozzles, particularly on the outlet surfaces and the separation edges
must be removed with care.

Nozzle lances displaying the following signs of damage may need to be replaced:
- Damaged weld seams, weld points, cracks, breaks
- Mechanical damage on the sealing surface of the mounting flange
- Mechanical damage to the connections for operating media
- Deformations
- Advanced abrasion which impairs the functioning or safety of the nozzle lance.
- Advanced corrosion which impairs the functioning or safety of the nozzle lance.
- Mechanical damage on the sealing surface of the nozzle connection (can be
recognised when the nozzle is disassembled).

8.3.2 Cleaning the nozzle lance

Deposits can build up on the surface of the nozzle lances in the duct and have a negative
effect on the spray quality. These deposits are to be removed with care from the nozzle
lances and in particular from the critical areas. In order to check that the nozzles are once
again spraying properly, a spray test must be subsequently performed.

Prerequisite:
 Nozzle lance has been disassembled and has cooled down.
 Use protective equipment: Protective clothing, safety shoes, protective gloves, safety
goggles.

This requires:
 1x soft-bristled cleaning brush for the nozzle
 1x stainless steel wire brush

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 1x cloth
 Water for cleaning

Carry out the following steps:


1) Clean the nozzle lance up to but not including the nozzle with the stainless steel wire
brush.
2) Carefully clean the nozzle with the soft-bristled cleaning brush and water.
3) Perform the spray test.

8.3.3 Spray test

The spray test serves to check the spray characteristics of the nozzle and the operating
values as per the nozzle's pressure-volume diagram. If necessary, the nozzle must be
disassembled, cleaned or replaced.

Prerequisite:
 Nozzle lance has been disassembled and has cooled down.
 The correct supply and disposal of media is ensured.
 Use protective equipment: Protective clothing, safety shoes, protective gloves,
protective helmet and safety goggles.

This requires:
 Jack stand or similar tool to support the nozzle lance (must be suitable for the actual
load)
 A vice or similar tool to clamp the nozzle lance.
 Nozzle pressure-flow rate diagram.

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WARNING
Risk of injury from the uncontrolled movement of parts
Nozzle lances and high pressure hoses which are not properly secured can
become loose during the spray test. Loose nozzle lances and high pressure
hoses will move in an uncontrolled manner when under pressure. Moreover,
parts can be projected out. There is a risk of injury or even death.
→ Clamp the nozzle lances in a suitable fixture.
→ Prior to commencing the spray test, ensure that all the parts are properly
secured and that the high pressure hoses are connected correctly.
→ Only disconnect the high pressure hoses from the nozzle lances when the
former are depressurised.

WARNING
Risk of injury from the flow of liquid under high pressure
If the flow of liquid penetrates orifices at high pressure, this can result in serious
injuries. Moreover, touching the flow of liquid under high pressure or at high
temperature can result in serious injuries.
→ Never direct the flow of liquid at persons.
→ Never hold your hand in the flow of liquid if the nozzle lance is being
operated at a high pressure or temperature.
→ Use suitable protective equipment as specified.

WARNING
Risk of injury from swirled up parts
Parts which are hit by the high-pressure jet may be swirled up and injure
individuals.
→ Use suitable protective equipment as specified.
→ Ensure that the operating media are conducted away safely.

WARNING
Risk of injury from electric shock, chemical burns, poisoning
If the jet is directed towards live parts, acid baths or similar, this can result in
serious or even fatal injuries. There is a risk of poisoning when using media
which is hazardous to health.
→ Never direct the jet at sensitive system components such as live parts,
electrical devices, acid baths or similar.
→ Only use safe media.

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WARNING
Risk of injury from noise
The spray test creates noise. At higher pressures in particular there is a risk of
hearing damage.
→ Use suitable ear protection.

Carry out the following steps:


1) Remove the nozzle lance from the CFB-reactor, and clamp and support it in a vice.
2) Re-connect the water accessory (back flow and feed flow) to the nozzle lance.
3) Open the gang valve assembly and, if necessary, other shut-off valves.
→ If individual streaks are visible in the spray pattern (see image) or larger drips form at
the nozzle: Clean or replace the nozzle.

Spray pattern: good (left), poor (right).

→ If the values of the spray test deviate significantly from the performance data of the
spillback nozzle (refer to the pressure diagram) even though the required water
pressure is provided by the operator for the respective operating point, check the
nozzle lance for leaks and blockages.
4) Close the gang valve assembly in the water accessories.

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8.3.4 Repairing the sealing surface at the supply pipe

The pressure applied to the grooved seal may gradually damage the sealing surface of
the supply pipe. Use a sharpening stone to repair the damaged sealing surface.

Carry out the following steps:


1) Place the sharpening stone flat on the sealing surface of the supply pipe.
2) Use a circular motion to grind the sealing surface smooth.

8.3.5 Nozzle

Check the nozzle for corrosion and wear during each nozzle lance maintenance cycle. If
necessary, replace the nozzle.

Spillback nozzle

Legend
No. Designation
1 Housing
2 Sealing ring
3 Mouth piece
4 Swirl insert
5 Sealing ring (grooved seal)

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8.3.5.1 Disassembling the nozzle

Prerequisite:
 Nozzle lance has been disassembled and has cooled down. Protection tube is un-
installed.
 Suitable protective equipment: Wear heat-resistant protective gloves.

This requires:
 Jack stand or similar tool (must be suitable to support the actual load of the nozzle
lance)
 1x vice or similar tool (to clamp the nozzle lance).
 1x hook spanner with pin (cap ø= 40-42 mm, pin ø=4 mm) (for the swirl insert)
 1x hook spanner with lug DIN1810 B-shape (cap ø=80-90 mm, lug ø=6 mm) (for the
protective cap)
 1x open-ended spanner (55 AF) (for the housing).

NOTICE
Damage to the nozzle due to incorrect handling
The atomization quality depends on the properties of the nozzle. Incorrect use
may damage the outlet surfaces or separation edges of the nozzle.

→ Handle the nozzle with great care.


→ Only use suitable tools. Never use hard, sharp-edged tools to clean the
nozzle.
→ Allow the nozzle lance to cool down before disassembling the nozzle.

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Carry out the following steps:


1) Clamp one end of the nozzle lance in the vice and support the other end. The nozzle
faces downwards.

2) Use the hook spanner to loosen the protective cap from the protection tube.

3) Remove the protective cap.

4) Use the open-ended spanner to loosen the housing.

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5) Disassemble the housing together with the gasket and orifice. The gasket and orifice
fit loosely in the housing.

6) Remove the gasket and orifice from the housing

7) Use the hook spanner to free the swirl insert from the inner pipe.

8) Disassemble the swirl insert with the sealing ring (grooved seal).

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9) Remove the sealing ring (grooved seal) from the swirl insert.

8.3.5.2 Visual inspection

Cleaned nozzle lances without visible damages do not have to be replaced. Damaged
nozzles or nozzle components must be replaced.

Check the following criteria:


- Separation edge damaged or deformed?
- Deposits on the separation edge?
- Deposits on the geometric configuration of the nozzle orifice?
- Thread damaged?
- Sealing surfaces damaged?
- Sealing rings deformed, worn?
- Water borehole blocked in the swirl insert?
- Abrasion visible?
- Corrosion visible?

8.3.5.3 Clean the nozzle

Use a soft-bristled brush and water to remove light soiling. If the nozzle is heavily fouled,
immerse it in an ultrasonic bath with water or a citric acid solution first. Pay attention to the
manufacturer's safety instructions.

After cleaning a spray test must be performed to check whether the nozzle sprays
properly. If it’s necessary cleaning must be repeated or the nozzle replaced.

Prerequisite:
 Nozzle has been disassembled.
 Use protective equipment. When using a citric acid solution, additionally wear
protective clothing, protective gloves and safety goggles.

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This requires:
 1x soft-bristled brush
 1x cloth
 Water for cleaning
 If necessary, an ultrasonic bath for cleaning
 If necessary, a citric acid solution 10(water):1(citric acid) for soaking the nozzle.

CAUTION
Risk of injury due to incorrect handling of the citric acid solution
→ Use suitable protective equipment: protective clothing, protective gloves,
safety goggles.
→ Work with the utmost care and attention to detail.

CAUTION
Risk of injury due to incorrect handling of the ultrasonic bath
→ Pay attention to the manufacturer's operation manual.
→ Use suitable protective equipment: protective clothing, protective gloves,
safety goggles.
→ Work with the utmost care and attention to detail.

Carry out the following steps:


1) Immerse the nozzle in an ultrasonic bath with water or in a citric acid solution to
remove stubborn dirt or grime. Subsequently flush the nozzle with water.
2) Clean the nozzle thoroughly with water and a soft-bristled brush.

8.3.5.4 Assembling the nozzle

Only assemble nozzles that are in efficient working order. Always replace damaged
sealing rings. Do not use the same sealing rings more than three times. After assembly,
make sure the nozzle is leak tight.

Prerequisite:
 Nozzle is cleaned.
 Nozzle shows no visible signs of damage.
 The sealing surface at the supply pipe is not damaged.

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This requires:
 Jack stand or similar tool (must be suitable to support the actual load of the nozzle
lance)
 1x vice or similar tool (to clamp the nozzle lance).
 1x open-ended spanner (55 AF) (for the housing).
 1x torque wrench with open-ended spanner attachment (55 AF)
 1x hook spanner with pin (cap ø= 40-42 mm, pin ø=4 mm) (for the swirl insert)
 If necessary, new gaskets for the nozzle.
 Thread paste (compatible with the atomized liquid and the maximum operating
temperature) and a brush.

NOTICE
Damage to the nozzle due to incorrect handling
Incorrect use may damage the outlet surfaces or separation edges of the
nozzle.
→ Handle the nozzle with great care.
→ Only use suitable tools.

Carry out the following steps:


1) Clamp one end of the nozzle lance in the vice and support the other end. The nozzle
faces downwards.

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2) Push the sealing ring (grooved seal) onto the swirl insert.

3) Lightly coat the internal thread of the swirl insert with thread paste.

4) Screw the swirl insert with the sealing ring onto the return pipe of the nozzle lance until
the sealing ring sits on the sealing surface of the supply pipe (centred above the collar
at the swirl insert).

5) Tighten the swirl insert.


→ Tightening torque approx. 20-30 Nm (hand tight).

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6) Place the sealing ring in the housing.

7) Place the orifice in the housing.

8) Lightly coat the external thread of the supply pipe with thread paste.

9) Screw the housing onto the supply pipe.

10) Tighten the housing.


→ Tightening torque 200 Nm.

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8.3.5.5 Checking the nozzle for leaks

After assembling the nozzle, a spray test must be carried out (outside the CFB-reactor) in
order to check the nozzle for leaks. During the spray test, operate the nozzle lance with
the back flow both fully open and fully closed.

Prerequisite:
 Nozzle lance is disassembled.
 Nozzle has been assembled.
 The correct supply and disposal of media is ensured.

This requires:
 Jack stand or similar tool to support the nozzle lance (must be suitable for the actual
load)
 A vice or similar tool to clamp the nozzle lance.
 1x open-ended spanner (55 AF) (for the housing)
 1x torque wrench with open-ended spanner attachment (55 AF)
 1x hook spanner with lug DIN1810 B-shape (cap ø=80-90 mm, lug ø=6 mm) (for the
protective cap)

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WARNING
Risk of injury from the uncontrolled movement of parts
Nozzle lances and high pressure hoses which are not properly secured can
become loose during the spray test. Loose nozzle lances and high pressure
hoses will move in an uncontrolled manner when under pressure. Moreover,
parts can be projected out. There is a risk of injury or even death.
→ Clamp the nozzle lances in a suitable fixture.
→ Prior to commencing the spray test, ensure that all the parts are properly
secured and that the high pressure hoses are connected correctly.
→ Only disconnect the high pressure hoses from the nozzle lances when the
former are depressurised.

WARNING
Risk of injury from the flow of liquid under high pressure
If the flow of liquid penetrates orifices at high pressure, this can result in serious
injuries. Moreover, touching the flow of liquid under high pressure or at high
temperature can result in serious injuries.
→ Never direct the flow of liquid at persons.
→ Never hold your hand in the flow of liquid if the nozzle lance is being
operated at a high pressure or temperature.
→ Use suitable protective equipment as specified.

WARNING
Risk of injury from swirled up parts
Parts which are hit by the high-pressure jet may be swirled up and injure
individuals.
→ Use suitable protective equipment as specified.
→ Ensure that the operating media are conducted away safely.

WARNING
Risk of injury from electric shock, chemical burns, poisoning
If the jet is directed towards live parts, acid baths or similar, this can result in
serious or even fatal injuries. There is a risk of poisoning when using media
which is hazardous to health.
→ Never direct the jet at sensitive system components such as live parts,
electrical devices, acid baths or similar.
→ Only use safe media.

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WARNING
Risk of injury from noise
The spray test creates noise. At higher pressures in particular there is a risk of
hearing damage.
→ Use suitable ear protection.

WARNUNG
Risk of serious injury and death due to incorrect execution of the spray
test
→ Clamp the nozzle lance in a suitable fixture.
→ Select a safe spraying direction: Never point the nozzle lance at people or
sensitive system components, e.g. acid baths, live parts.
→ Only use a non-hazardous, harmless liquid, e.g. mains water.

WARNING
Risk of injury due to pressurized parts
The nozzle lance is supplied with high-pressure operating media through
suitable high pressure hoses. Disassembled high pressure hoses under high
pressure will move in an uncontrolled and random manner. There is a risk of
serious injury and death.
→ Only disconnect the accessories when the accessories are depressurized.
→ Fasten the high pressure hoses.

Carry out the following steps:


1) Clamp and support the nozzle lance in a vice.
2) Re-connect the water accessory to the nozzle lance.
3) Open the gang valve assembly and, if necessary, other shut-off valves.
→ Nozzle lance is put into operation
4) Check for potential leaks with the back flow open and closed:
- Between the housing and the orifice.
- Between the internal thread of the housing and the external thread of the nozzle
lance.
5) Close the gang valve assembly in the water accessories.
→ If leaks occur between the housing and the orifice:

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a) Tighten the housing again.


b) If the leak continues: Disassemble the nozzle, clean thoroughly and replace the
sealing ring.
c) Check the sealing surface between the orifice and the swirl insert. Replace
damaged components.
d) Re-assemble the nozzle.
e) Perform the spray test again and check for leaks.
→ If leaks occur between the internal housing thread and the external thread of the
nozzle lance:
a) Disassemble the nozzle, clean thoroughly and replace the grooved seal.
b) Check the sealing surface on the outer pipe (supply line) of the nozzle lance and
repair if damaged.
c) Re-assemble the nozzle.
d) Perform the spray test again and check for leaks.
6) Lightly coat the external thread of the protection tube with thread paste.

7) Screw the protective cap onto the protection tube and use a hook spanner to tighten it.

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8.3.6 Non-return valve

Dirt, wear or damage may cause the non-return valve to become blocked or leak. This
prevents optimal control of the injection system. Check the non-return valve on a regular
basis. If necessary, replace the non-return valve.

8.3.6.1 Checking for leaks

The non-return valve can be checked for leaks when the return line is pressurized,
e.g. when simultaneously operating several nozzle lances. In this case, operation of the
respective nozzle lance is interrupted and the return line is disassembled from the nozzle
lance.

If the non-return valve is leaky, pressurized water may escape from it. Be particularly
careful and cautious.

Also observe the information from the non-return valve manufacturer. This information is
provided in the supplied documentation.

Prerequisite:
 Injection system is in operation (return line is pressurized).
 The correct supply and disposal of media is ensured.

This requires:
 1x ring or open-ended spanner (65 AF)
 1x ring or open-ended spanner (70 AF)
 Suitable fixture for attachment of the high pressure hose (back flow).

WARNING
Risk of serious injury and death due to incorrect execution of the tight-
ness test
If the non-return valve is leaky, pressurized water may escape from it. There is
a risk of serious injury and death.
→ Be particularly careful and cautious.
→ Ensure that the spray goes in a safe direction.
→ Attach the hoses securely.
→ Only disconnect the high pressure hoses after they are fully depressurised.

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Operation and Maintenance Manual
Cochrane
Spillback Nozzle Lances

Carry out the following steps:


1) Close a gang valve assembly.
2) Once the pressure is relieved, open the quick-release coupling on the return line and
remove the high pressure hose.
3) Fasten the high pressure hose securely to perform the tightness test. Ensure that the
spray is directed safely.
4) Slightly open the gang valve assembly.
→ No water seeps from the high pressure hose: The non-return valve is leak tight.
→ Water flows from the high pressure hose of the back flow: The non-return valve is not
leak tight. Continue with the following step.
5) Close the gang valve assembly.
6) Disassemble and clean the non-return valve.
7) Assemble the non-return valve and carry out the test again.
→ If the non-return valve still leaks, replace it and carry out the test again.

8.3.6.2 Checking for blockages

The test to ensure that the non-return valve isn't blocked is performed via a spray test
outside of the duct. The respective nozzle lance is taken out of operation and sprayed
outside the duct.

Prerequisite:
 Nozzle lance is disassembled.
 The correct supply and disposal of media is ensured.

This requires:
 A vice or similar tool to clamp the nozzle lance.
 Suitable fixture for attachment of the high pressure hose (back flow).
 1x ring or open-ended spanner (65 AF)
 1x ring or open-ended spanner (70 AF)

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Reproduction, transfer or distribution of part or all of the contents in any form without prior written permission of Doosan Lentjes GmbH is
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Operation and Maintenance Manual
Cochrane
Spillback Nozzle Lances

WARNUNG
Risk of serious injury and death due to incorrect execution of the spray test
→ Be particularly careful and cautious.
→ Ensure that the spray goes in a safe direction.
→ Attach the hoses securely.
→ Only disconnect the high pressure hoses after they are fully depressurised.

Carry out the following steps:


1) Clamp and support the nozzle lance (in a safe spraying direction!).
2) Re-connect the water accessory (back flow and feed flow) to the nozzle lance.
3) Open the gang valve assembly.
4) Slowly close the return line (control valve, shut-off valve).
→ The weak jet becomes a powerful stream. The non-return valve is working correctly.
→ The jet does not alter. The non-return valve is probably blocked and the nozzle lance
operates permanently at the maximum injected flow rate. Continue with the following
step.
5) Close the gang valve assembly.
6) Disassemble and clean the non-return valve.
7) Assemble the non-return valve and carry out the test again.
→ If the non-return valve is still blocked, replace it.
→ If the non-return valve is in correct working order and the spray pattern does not alter
under the said conditions, look for a different cause (e.g. shut-off valve closed in the
return line).

8.3.7 Cleaning the strainer

The strainer insert becomes dirty over time. Clean the strainer insert on a regular basis. If
necessary, replace the strainer insert.

The respective nozzle lance must be put out of operation before cleaning the strainer. The
strainer insert must be disassembled and cleaned with water.

This requires:
 1x open-ended spanner (32 AF)
 Seal, if necessary
 Strainer insert, if necessary.

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Reproduction, transfer or distribution of part or all of the contents in any form without prior written permission of Doosan Lentjes GmbH is
prohibited.
Operation and Maintenance Manual
Cochrane
Spillback Nozzle Lances

Carry out the following steps:


1) Close the gang valve assembly.
2) Use an open-ended spanner to open the screw plug.
3) Disassemble the screw plug with the gasket.
4) Remove the strainer insert.
5) Flush the strainer insert with water.
6) Re-assemble the strainer insert, gasket and screw plug.
7) Use a suitable open-ended spanner to tighten the screw plug.

8.3.8 Inspecting the high pressure hoses

Check the accessories during each nozzle lance maintenance cycle. If necessary, replace
the high pressure hoses.

Do not use the high pressure hoses for more than six years. During this period, do not
store the high pressure hoses for longer than two years. The service life is shorter if the
high pressure hoses are used at the upper end of the permissible load range or stored
incorrectly.

The date of manufacture is specified on the sleeves of the high pressure hoses (e.g.
STH1211 = December 2011.

The functional capability of the high pressure hoses must be determined by the operator
and checked at intervals according to local conditions, statutory requirements and the
relevant regulations as specified by DIN 20066.

Always replace the high pressure hoses if you detect the following damage:
- Outer layer damaged down to the inlay?
- Outer layer brittle? Crack formation?
- Deformation? Blistering?
- Leaks?
- Damage or deformation to hose fittings which may impair leak tightness?
- Do the high pressure hose slip from the hose fitting?
- Visible corrosion that impacts on mechanical properties and strength?
- Storage and service life exceeded?

Document No. Contractor: A.23001-1-05330-MOM-LUE-0002 Rev. 96 of


Document No. Employer : 62-13-132-1_l_oi_v0_15-04-10 00 99
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Reproduction, transfer or distribution of part or all of the contents in any form without prior written permission of Doosan Lentjes GmbH is
prohibited.
Operation and Maintenance Manual
Cochrane
Spillback Nozzle Lances

8.4 Spare parts

WARNING
Risk of injury from use of incorrect spare parts
The use of incorrect or defective spare parts can present risks to people.
Furthermore, this could result in damage to property and malfunctioning.
→ Only use original spare parts.

Product number Qty. S W Designation Delivery


period
(weeks)
P800.117.82.00.00.0 2 X Spillback nozzle lance complete with nozzle 12-14
and quick-release coupling
P261.036.1Y.78.00.Z 2 X Spillback nozzle 12-14
261.036.4H.78.02.Z 5 X Spillback nozzle – orifice 12-14
261.036.Q9.78.06.0 5 X Spillback nozzle – swirl insert 10-12
095.015.1Y.05.07.0 10 X Sealing ring 3-4
095.015.71.04.41.0 10 X Sealing ring 3-4
815.011.R6.1N.50.0 2 Protective cap 12-14
9ET.048.29.00.00.0 2 X Thread paste (white, 40g) 2-3
9ET.047.03.00.00.0 1 Hook spanner for swirl insert 2-3
9ET.047.12.00.00.0 1 Hook spanner for protective cap 2-3
9ET.084.40.0B.08.0 2 X Accessory DN40 PN40 6-8

8.5 Lubricating/Greasing

8.5.1 Spillback Nozzle and Nozzle Lance

The threads on the nozzle lance should be smeared with stainless steel grease before
assembly. This prevents thread corrosion. Ensure that the grease is of a composition
suitable for the fluid sprayed and the operating temperature.

The quick release couplings are to be lightly greased after being opened for cleanings,
and the O-rings if necessary.

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Reproduction, transfer or distribution of part or all of the contents in any form without prior written permission of Doosan Lentjes GmbH is
prohibited.
Operation and Maintenance Manual
Cochrane
Spillback Nozzle Lances

Equipment Lubrication Kind of Lubrication Quantity of Replacement Remarks


Point Lubrication symbol to lubrication of lubricant
DIN51502 per after service
lubrication hours
point (kg)
Connection Thread Grease Klüber UH1 each nozzle Suitable grease
Lance - Nozzle 96-402 assembling (composition
suitable for the
fluid sprayed)
Quick Release O-Ring Grease Klüber UH1 monthly Suitable grease
Coupling - Plug 96-402 (composition
suitable for the
fluid sprayed)

8.5.2 Other Equipment

The lubricating and greasing of the other equipment are listed in the corresponding
operating and maintenance instructions (see Technical Documentation TD/17.01).

Document No. Contractor: A.23001-1-05330-MOM-LUE-0002 Rev. 98 of


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Reproduction, transfer or distribution of part or all of the contents in any form without prior written permission of Doosan Lentjes GmbH is
prohibited.
Operation and Maintenance Manual
Cochrane
Spillback Nozzle Lances

9 Appendix

Refer to Technical Documentation TD/17.01.

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Reproduction, transfer or distribution of part or all of the contents in any form without prior written permission of Doosan Lentjes GmbH is
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Document Coversheet

Document designation: Lance Accessories


Drawings and Parts List

Leading Code 11HTQ20BN001


___________________________________________________________________________

Codes which are also 11HTQ20BN002


applicable: 11HTQ20BN003
11HTQ20BN004
11HTQ20BN005
21HTQ20BN001
21HTQ20BN002
21HTQ20BN003
21HTQ20BN004
21HTQ20BN005

Rev Issued Prepared Check Q-Check Approval Description

00 14.04.2015 J.Barthel G.Frick - - First Issue

01

02

FGD CFB Cochrane A.23001 A.23001-0-05330-MTD-LUE-0001 00


Plant Order No. Document Number Rev.