ENG.TYPE 18V32CLX xX 3SETS B220655 6200kWe xX 3SETS DIESEL GENERATING PLANT FOR CHI MEI CORPORATION INSTRUCTION MANUALS DRAWING TITLE : EXHAUST GAS BOILER DRAWING No. : P8860112A NIIGATA ENGINEERING CO., LTD POWER SYSTEMS DIVISION POWER PLANT ENGINEERING DEPARTMENTINSTRUCTION MANUAL EXHAUST GAS BOILER TYPE 3X4R + SKID CLAYTON INDUSTRIES CLAYTON OF BELGIUM N.V. RIJKSWEG, 30 B-2880 BORNEM (B) TEL. : (03) 890.57.00 FAX : (03) 890.57.01 Clayton de France S.a.r.. Clayton Thermal ProductsLtd. Clayton Deutschland GmbH. 2, Rue du Ventoux Tatton Court, 3 Untergath 190, 2.1, Petite Montagne Kingsland Grange, Woolston 47805 Krefeld CE. NO 1233, Warrington WA 4RW. Deutschland 91019 EVAY-Cedex England Tel. : (02151) 540001 France Tel. (0925) 823 123 Fox, : (02151) 54 26 26 Tél 1) 6077 02 50 Fax: (0925) 817 373 Fax 11) 6077 01.11 Clayton Nederland B.V. Clayton Scandinavia AS Celsiusstraat, 5 Enggatan, 34 3316 AC Dordrecht 2301 Hamar Nederland Norway Tel. 078) 139 811 Tel. : (62) 53 38.77 Fax 1078) 139 347 Fax: (62) 52 57 26 16.116 - C7/02/95INSTRUCTION MANUAL EXHAUST GAS BOILER TYPE 3X4R + SKID CLAYTON INDUSTRIES Clayton de France S.a.r. 2, Rue du Ventoux 2.1. Petite Montagne CE. N° 1433 91019 EVRY-Cedex France Tél. -: (1) 6077 02 50 Fax: (160770111 Clayton Nederland B.V. Colsiusstraat, 5 3316 AC Dordrecht Nederland Tel. (078) 139 811 Fax: (078) 139 347 16.116 - 07/02/95 CLAYTON OF BELGIUM N.V. RIJKSWEG, 30 B-2880 BORNEM (B) TEL. : (03) 890.57.00 FAX : (03) 890.57.01 Clayton Thermal Products Ltd. Tatton Court, 3 Kingsland Grange, Woolston Warrington WA1 4RW England Tel. (0925) 823 123 Fax: (0925) 817 373, Clayton Scandinavia AS Enggatan, 34 2301 Hamar Norway Tel (62) 53 38 77 Fax: (62) 5257 26 Clayton Deutschland GmbH Untergath 190 47808 Krefeld Deutschland Tel. (02151) $4 00 01 Fax. ; (02181) 54 26 26Introduction Chapter 1: Technical specifications 1.1 Exhaust gas boiler : 1a 1.2 Skid with 3 accumulators & 4 pumps . . 1 Chapter 2: Description water & steam system 2.1 Flow .. 24 2.2 Recirculation pump . 24 2.3 Accumulator ... 2.2 2.4 Feedwater supply 2.2 Chapter 3: Electrical system a1 Deccriction(conmonents 2907 ad Sit | Exhaust gas boiler Aid a1 eee OURO eeee cece cece cara arcar eararearaareassarcaceaee sca: seeenes 31 ae esecenare 3.2.2 Starting the exhaust gas boiler skid 8 Chapter 4 : Operation 4.1 Starting & stopping plant. 44 4.2 Freezing precautions . . 4.2 EFL16116 (page 1 to 9) Chapter 5 : Periodic maintenance Sl Genel 5a 5.2 Feedwater treatment . . 5 5.3 Service daily ........ 5.1 ae Feedwater control 5.1 aoe Steam pressure and feedwater pressure 5 5.3.3 Sootblow . 5.1 5.3.4 Walk aroun 5.2 5.3.5 Oil level in crankcase of waterpump . 5.2 wererce:‘TABLE OF CONTENTS: 5.4 5.5 5.6 Weekly maintenance: 35s Monthly maintenance .. 6.6.00 eee ee eee eee eee ee st eeeeee e 5.5.1. Feedwater pressure at normal operating conditions ...... . 5.5.2 Waterpump heads and columns . . 5.5.3 Level control and gauge glass. Service annualy ........sscececsosccsesorere hence eee Chapter 6 ; Component maintenance 6.1 6.2 63 Feedwater pump ...... 2.4. Sess ices ang 6.1.1. Pump check valve maintenance . 6.1.2 Replacing waterpump valve seats .. . . 6.1.3 Waterpump diaphragm replacement . . . 6.1.4 Waterpump 6.1.5 Waterpump oil level switch ........ 6.1.6 Waterpump relief valve.......... 065 6.1.7. Waterpump discharge snubber........ Removal of scale from restricted heating coil ........ Removal of excessive soot from heating coil... . . ADDENDUM : ER-1058_E.RA recommended oils for Clayton pumps 52 od 5.2 fe) 6.2 6.2 6.3 6.5 67 6.8 6.9 6.9 6.9 weieace.ZODUCTION = GENERAL This manual contains step by step instructions for operation and maintenance of the CLAYTON exhaust gas boiler. The given recommendations result from many years of experience in the manufacturing and service of this type of equipment. The efficiency and service of your Clayton exhaust gas boiler will depend upon strict adherence to these instructions. It is recommended that the operator studies this manual to gain a working knowledge of the equipment. The parts catalog contains illustrations which also serve as a valuable aid.eS (a CHARTER I rECHNICAL . SPECIFICATIONS ae 11 12 CEBU] 7 TECHNICAL EXHAUST GAS BOILER Type : aR Exhaust gas flow of diesel engine : 43900 Exhaust gas temperature 365 Steamflow 3000 Design pressure : 12 Operating pressure : 85 Plan dimension : 175130 Plan heating section 7 150460 Plan inlet duct : 150475 Plan outlet duct 7 150476 Plan steam collector 7 150484 Safety valve DN 25 Heating surface 219,2 Gas flow area : 1,22 Water content : 1300 ‘Weigt approx. (incl. in- and outlet duct): 6300 SKID with 3 ACCUMULATORS & 4 PUMPS Electrical specification 380/60/3, Plan dimension HE-7040 Plan accumulator : 150471 Flow diagram, : HE-4036 Wiring diagram : SW-1317 Safety valve : DN 25 Recirculation pump. 175128 Capacity 7 6000 Maximum discharge pressure 28 Motor : 18 hte kg/h °c kg/h bar bar rev.B mt kg rev.B rev. 4 rev. C (UH27939) im bar kwCHAPTER 2 © DESCRI TION WAT! 2.1 FLOW (see HE-4036) ‘Supply water and return condensate blend in the hotwell. The centrifugal (make-up) pump. Pumps the feedwater into the accumulators (43.1 - 43.2 - 43.3). The water level in the accumulator is controlled by the level switches (F214 - F215 - F216), which de-activates the motorized water supply valve (M316 - M317 - M318) when correct water level is achieved. It opens the valve again when water level is dropped, thus maintaining the correct level in the accumulator. When the motorized water supply valve is closed, the relief valve of the boiler feedwater module opens, allowing the water to return to the hotwell The recirculating pump (40.1 - 40.2 - 40.3) pumps the water directly from the accumulator into the heating coil, flowing through the spiral single-passage section in a direction opposite to that of the exhaust gases, where it is gradually heated to steam temperature. From the generating section the fluid goes into the separating nozzle in the accumulator, where through centrifugal force the dry steam is separated from the surplus liquid, which is returned to the bottom of the accumulator where it is blended with feedwater. In this way, it is assured that the temperature of the water entering the heating coils is always above the dewpoint of the exhaust gases, thus eliminating possible outside corrosion. A stand-by pump 140.4) is provided. When starting the plant, with the recirculation pump 1 (40.1), the following valves should be opened and/or closed: - open valve 54.14, - open valves 60.1A and/or 60.18 - open valve inlet section EGB - open valve outlet section EGB = open valve 47.1 (outlet accumulator) - close valve 82.1 (drain accumulator) + open valve 63.1 (blow down) - open valves 35.1A and 35.1B (steam trap) = open valve 46.1 (pressure switches) Replacing the recirculation pump 1 by the stand-by pump (40.4) the following valves should be opened and closed: - close valves 60.1A and 60.18 - close valve 54.1A ~ open valve 64.18 open valves 100.1A and 100.1B When starting the plant, with other recirculation pumps the similar valves should be opened and/or closed. 2.2 RECIRCULATION PUMP The double-diaphragm pump is designed to deliver a fixed amount of water into each heating coil. The amount of water is sufficient to allow maximum evaporating while maintaining a wet tube heating coil The pump is belt driven and does not contain any packing boxes. Corrossion-resistant spring, discs and seats are used in the check valve housings. Pressure pulsations are absorbed by discherge snubbers, which ensures stabilized delivery. A relief valve is provided to protect the pump against excessive pressure. aoe weiepce.eases eae: 24 a __ CHAPTER 2 : DESCRIPTION WATE TER & STEAM ‘SYSTEM ‘A tubular column separates the check valve housing from the pumping heads, thus preventing the diaphragms from excessive heat. The pump diaphragms are operated hydraulically by cil, displaced by reciprocating pistons within the pump. ACCUMULATOR The steam accumulator serves as a steam separator as well as a liquid storage for the system. A water level control is mounted on the accumulator which electrically controls water supply solenoid valve in accordance with system demand. Fluid entering the accumulator from the heating coil is discharged through a separating nozzle where steam is released and excess liquid is contrifugally separated, passing to the lower section. This positive control of separation will prevent carry over of liquid into the steam lines. A steamtrap is mounted to carry off excess water due to changes in diesel output. To keep the concentration of dissolved solids in the liquid within the required limits, a blowdown valve (Y232 - Y233 - 234) has been foreseen, FEEDWATER SUPPLY Feedwater supply is provided by a centrifugal pump on the feedwater skid. A second (stand- by) pump is provided. =2.2- ror100-€63.1 DESCRIPTION COMPONENTS: 341 EXHAUST GAS BOILER SKID (see wiring diagram SW-1317 rev. ©) For the functional description of the components we refer to the function description ‘on pages 16 thru 20 on the electrical wiring diagram 3.2 OPERATION 3.21 3.2.2 BEFORE STARTING open inlet and outlet valves of the selected centrifugal pump on the feedwater skid open outlet valve of the selected chemical pump on the feedwater skid open vaive prior to the relief valve on the feedwater skid STARTING THE EXHAUST GAS BOILER SKID (HE-4036 rev.4) eae Fimportent that ion be re the dadal never b 34 wor 68-€4.1 STARTING & STOPPING PLANT « see attached flowchart EFL16116 (numbering dampers > see figure below) BY-PASS VALVE INSTALLATION werecee- Sate4.2 FREEZING PRECAUTIONS + Drain system completely - Remove all tubes in the water and steam system in which a low sump may contain water. = Ofen drain cocks at base of waterpumps. = Remove intake and discharge check valves from the recirculation pump. + After making sure that all water has been drained, replace all parts and close valves. + Drain feed water tank completely. -4.2- isiiecee.Customer supply Pump running NOTE: Before starting, the hotwell must be filled with treated water and chemical dosing pumps in operation START ori Alarm + — stop > Chemical dosing pumps| Select feedpump 0 Alarm + vero Ves Alarm + stop pump2 stop 6 Pump running EFL16116 EGB2 Page 1( 5se2 ) Aut start logic Manual start | a Camper \ no Alarm + closed stop Yés Bamper~ yo Alarm + closed stop Yés FFL 16116 Customer start signal (Preparation for lengine start signal) Page 2¢ EGB2 ) amper A yo, Alarm + ‘open stop Yes pen chose Level controll = valve ves Alarm + stop 4 FFL16118 Page 3TA ‘gastemp <150°C. Alarm + High. ae ok Pump selection al / EGB 2 crc pump. Standby circ. pump. Alarm + stop EGB2 FFL 16116 Page 4Damper 4 open (aed) Customer start signal (Engine Running ‘Signal) Manual start Aut start logic (m) oe ko i. famper“t closed Yes EGB2 (Close damprt dampr2 Open dampr3 Alarm + stop Page 8EGB2 Campero Alarm + closed stop Yes FampeP yo, Alarm + open stop Yes Stop circ. pump EGB2 EFLI8116 Page 95A 5.2 5.3 a a GUARIE 5: "PERIODIC MAIN: GENERAL Like any other piece of mechanical equipment, the CLAYTON exhaust gas boiler must receive periodic inspection and attention to maintain the efficiency and service it is designed to perform. The following service recommendations require a few minutes each day and will maintain the efficiency of the unit and minimize repairs and replacements. FEEDWATER TREATMENT The importance of feedwater treatment is discussed in detail in the "FEEDWATER TREAT- MENT MANUAL" (ref. number 191.087). To prevent internal corrosion and to eliminate scale formation, proper control of feedwater must be given serious consideration before start-up. SERVICE DAILY 5.3.1. FEEDWATER CONTROL Test feedwater according to the specifications of the "Feedwater Treatment Manual” (ref. number 191.087) 5.3.2 STEAM PRESSURE AND FEEDWATER PRESSURE Record steam pressure and feedwater pressure. By comparing steam and fsedwater pressure at full load with those recorded at initial startup, coil restrictions can be noted. 5.3.3 SOOTBLOW Sootblow should be effectuated every 8 hours of operation, For this purpose a waterwash spray pipe is mounted in the inlet duct. The engine must operate at normal load. To drain off excess water, a drain connection situated beneath the boiler has been provided. Slowly open water valve. Close valve after appr. 5 minutes (a restrictor is provided to limit the amount of water sprayed into the boiler). This restrictor must be set for the correct amount of water at initial start-up of the installation). The above procedure should be repeated every time when gas temperature at boiler outlet has increased more then 30°C with reference te the gas outlet temperature at normal operation conditions. Proceed as follows : = Operate plant at normal pressure - Open soot blower valve. Sootblow for 30 seconds. = Allow plant to recover for 2 minutes and sootblow for another 30 seconds period -8.1- lenevee-__enarren 5 + rerionic mamrenance Se = Close soot blower valve. = After completion of the sootblow and return to normal operation, verify that the soot blower valve is fully closed. This. operation must be repeated at more frequent intervals if a bad sooting condition persists. If excessive soot has been allowed to gather on coil, refer to "Removal of excessive soot from heating coil in chapter 6. {On mokiple installations with steam discharge equipped | a with toate ane Careers | ee ee ave 5.3.4 WALK AROUND INSPECTION Check for leaks and/or unusual noises. 5.3.5 OIL LEVEL IN CRANKCASE OF WATERPUMP. Check oil level in crankcase of waterpump. During normal operation the switch lever should be in an approximately horizontal position. Add oil when necessary. For appropriate oils, see appendix 5.4 WEEKLY MAINTENANCE - Partially drain hotwell. Open drain valve for 1 minute (this can be done during normal operation, water level should be kept in sight in the gauge glass). In this way, sludge on the bottom of the hotwell is removed. = This may be omitted if total dissolved solids’ (TDS) readings are stable and within desired range. A properly adjusted rate should maintain the total dissolved solids (TDS) level in the feedwater to the pump at 3000 - 5000 ppm. If this level is exceeded, manually blowdown and re-adjust valve. 5.5 MONTHLY MAINTENANCE 5.5.1 FEEDWATER PRESSURE AT NORMAL OPERATING CONDITIONS Check coil feed pressure at normal load conditions, Record and compare with original reading for indication of internal scaling (normal feed pressure may vary slightly with each installation and it is advisable to carefully note the pressure immediately after the exhaust gas boiler is installed so that an accurate check of coil restriction can be made for the particular unit). Always note feed pressure after the exhaust gas boiler has operated for 30’ and is thoroughly heated, and always at the same operating steam load, feedwater temperature and at full load. -5.2- rerveve,5.5.2 5.5.3 . PERIODIC HAPTER 5 MAINTENANCE Coil restriction is indicated if feed pressure is 2 bar or more above the normal feed Pressure noted immediatey after installation or when the coil was completely clean, For example, if it is noted that feed pressure was 10 bar at a given steam pressure when the unit was in new condition, remove scale from heating coil when this pressure rises to 12 bar. If rising feed pressure is noted within 10 to 30 days after initial installation, teke steps immediately to correct the cause and prevent future trouble. Carefully consider the following + Carefully check to be sure feedwater treatment is adequate and is being used properly and consistently. Feed water treatment must be consistent and continuous. - See that the water softener is being regenerated at regular intervals. Blowdown the plant more frequently. It is sometimes necessary to blowdown more often than specified in this manual to remove solids which are precipitated in the form of sludge. The blowdown operation is not a cure of all but it will avoid formation of scale and thereby delay coil restriction. WATERPUMP HEADS AND COLUMNS Open drain cocks at base of recirculation pump until clear water appears. If heavy accumulation of sludge is present, repeat this operation more frequently, If drain cocks are plugged, remove cocks and use a stiff wire to dislodge sediment. | cau ON baat wi ee ce “iran cocks ee OIL LEVEL SWITCH. To be tested when installation is cold. Remove housing cover. With pump operation use an insulated rod and gertly move lever arm up and down. The oil level switch should be activated, witin the limits shown, to secure the waterpump at both top and bottom points. During normal operation, the switch lever arm should be in approximately horizontal position. Add or remove lubricating oil to obtain correct level. (See appendix for suitable lubrication oil). “5.3 ter16-e€5.5.4 LEVEL CONTROL AND GAUGE GLASS To be checked when installation is cold. Drain and flush gauge glass and level control. Check operation of low level alarm switch and level switches. 5.6 SERVICE ANNUALY = Inspect waterpump checkvalves. Replace seats and discs if worn. + Replace waterpump diaphragms + Replace oil in crankcase. Every year (ofter under severe conditions) drain and refill crankcase with new hydraulic oll (see appendix for suitable oils). -54- ss10ie.6.1 FEEDWATER PUMP t I lead a an ety Fig 6.1 : Waterpump assembly 4. Stand pipe 16. Return springs 26. Discharge springs 5. Check valve housing 17. Oil filter elbow 36. Nut (bearing cap) 10. Pump head 21. Valve seat 38. Pump piston 11. Drain cock 22. Valve discs 40. Crankcase 14. Diaphragm 23. Intake spring 42. Top plate & gasket 15. Diaphragm washer 25. Check valve caps 44. -6.1- Piston and link sentevee614 6.1.2 PUMP CHECK VALVE MAINTENANCE (see fig 6.1) a) Unscrew check valve caps from check valve housings and disassemble springs and discs from caps. Remove scale and pits from discs by rubbing them in a “figure 8° motion on a piece of fine sandpaper (wet-or- dry Nr 400 or finer) placed on plate glass. Discs must be pertectely smooth and flat for proper water pump operation. eee ae ee ee | ee send ach si ec an ron and possible deform a elects ne b) Inspect springs for distortion and free length. Free lenght of discharge springs should be 30 mm, free length of intake springs should be 25 mm. If not within Imm, replace spring. Also replace broken or distorted springs. ¢} Inspect seats for scored or damaged con 6.1.2) ion. Replace damaged seats \see chapter 4d) Scale may be removed from inside of check valve housings by filling the housings and pump columns with a solution of two parts water and one part Clayton Manufacturing Company KLEENKOIL or other properly inhibited scale-removing acid. Scale on springs and discs may be removed by immersing in the same solution. After scale has been dissolved, thoroughly flush parts with water. Open drain cock and flush pump columns. REPLACING WATER PUMP VALVE SEATS (see fig 6.2) To replace the valve seats, it will be necessary to use @ special seat puller (part nr UH25257 and a special seat driving tool (part nr UH18389) a) Adjust puller stem counterclockwise until jaws can be retracted into the body. Unscrew body nut sufficiently to allow retracted jaws to extend below valve seat when puller is inserted into check valve housing (see fig 6.2 A) b) Insert puller into check valve housing and turn stem clockwise in body, until jaws are fully extended below bottom of valve seat (see fig 6.2 B). ©) Hold body with wrench and turn body nut clockwise until valve seat is free of check valve housing (see fig 6.2 C). 4) Drive in new seat assembly using seat driving tool (see fig 6.2 D) using cere to avoid damaging seat face. 2) After seats have been properly installed, assemble springs to check valve discs. Install correct springs and caps in proper ports of check valve housing. -6.2- ssreeeCHAPTER 6 COMPONENT MAINTENANCE cone ha, OHS Met arlerd cutie Ul Fig 6.2 : Use of special seat puller and seat driver 6.1.3 WATERPUMP DIAPHRAGM REPLACEMENT a) Removal (see fig 6.1) = Remove drain cock and drain water from pump. Drain oil from cranckcase = Disconnect piping from pump. Unscrew hex nuts which secure pump heads to crankcase and remove check valve housings, pump heads and stand pipes as a unit, from each side of crankcase Remove diaphragm return springs, diaphragm washers and diaphragms Replace worn or deteriorated diaphragms. Replace broken or distorted springs. Free length of springs should be 132 mm. If not within 1 mm replace spring. -6.3- weriesee~PTER 6 b) Reassembly (see fig 6.1) = Position diaphragms, washers and springs to pump case and install pump heads. Tighten stud nuts as described below. Be sure springs and diaphragm washers remain in correct position during assembly. Torqueing sequence : Fig 6.3 : Torqueing sequence * = starting position. Apply torque as indicated in the table, through 7 cycles, using the above sequence for tightening TLLUSTRATION] NUMBER OF ToRaUE an STUD LOCATION (eee above Hstation 7 z 3 « 5 5 Tabs [Nm [tos [Wo [fobs | Nm [ibe] Nim [Ribs [ Wm [fees | im x i «0 [5s 20 | 58 x 2 [ao [a [ao [se [m0 [ar | 20 | a [oo] sa | 20 | a ® 3 [| se] oo | or | [se] 20] se | oo | o | wo] oa x + [eo [ a | 20 [ios | 00 |e | oo | a | oo | 109] oof er A [100 [736 | 100 | 136 | 400 [136 | 100 [ 196 | 100_| 196 [ 100 | 136 x 6 150] 203 | 180 [203 | 150 | 209 | 150 | 209 | 150 | 200 | 150 | 208 8 7 [200 an [200 [271 [200 [271 [200 | 271 | 200 [27s | 200 | 271 - Fill pump crankcase with hydraulic oil to proper level (see appendix for recommended oil). - IMPORTANT : After installation, operate plant normally for at least 24 hours. Then shutt down plant and allow to completely cool. Retighten all pump head nuts while pump is cold to take up set in diaphragms and prevent leakage. + 6.4~ weneues-6.1.4 WATERPUMP DISASSEMBLY AND REPAIR (see fig 6.1) 2) Disassembly Disconnect piping and tubing from pump at unions. Unscrew attaching screws and remove pump from frame. Remove weterpump heads, check valve housings, and diaphragms from pump. Remove oil level switch from pump case. Unscrew capscrews and remove top plate and gasket from pump crankcase. Unscrew nuts which attach bearing caps to front and rear of the crankease. Insert 3/8-16 screws into tapped holes in the bearing caps and carefully jack the caps away from the pump case. With the bearing caps removed, the crankshaft and attached parts can be removed through the top of the case. Pull bearings from each end of crankshaft. Slide pump pistons and links from the crankshaft. Note location of each piston and link to be sure they are installed into the same location when reassembling - Remove retaining rings from pump pistons. Disassemble spring retainers, springs and dises from pistons. - Remove bearing retainer and slide pinion shaft and gear from crankcase, Inspection = Inspect all bearings and bearing surfaces for worn or scored condition. Inspect pistons and cylinder walls for worn or scored condition. ~ Inspect valve discs and seats for scores or pits. Inspect springs for distortion or damage. Free lenght of discharge springs should be 30 mm, free length of intake springs should be 25 mm. If not within Imm, replace spring. Also replace broken or distorted springs. - Inspect oil seals and packings for worn or deteriorated sealing members, -6.5- wert6s86HAPTER | C: ‘ Repair + Replace piston and link assemblies if links or pistons are worn or damaged. Replace worn or scored crankshaft. - Scored discs may be resurfaced by rubbing them in a “figure 8" motion on a piece of fine sandpaper (wet-or- dry Nr 400 or finer) placed on plate glass. - Replace all other worn, scored, or damaged bearings and parts J) Reassembly ~ Install pinion shaft and gear with bearings assembled into pumpease and secure with bearing retainer. Check end play of pinion shaft. Endplay must be 0,2mm minimum to 0.4mm maximum. Add or remove shims to maintain this tolerance. Assemble disc, spring and spring retainer into pump piston and secure with retaining ring. Slide pump piston and link on the end of the crankshaft. Piston and link must be installed with the machined side of the link facing the gear end of the pump. - Assemble and secure main gear to crankshaft. Screws must be tigtened securely. Press cone sections of bearings on ends of crankshaft. Press cup sections of bearings into bearing caps. Place one 0.38 mm aluminium gasket on front bearing cap. Place one or more gaskets on rear bearing cap. These gaskets are used for clearance purposes and are available in three thick nesses - 0.13 mm, 0.25 mm , and 0.38 mm. As a trial, the first stackup should total at least 0.38 mm in thickness. ~ Carefully lower the crankshaft and attached parts into the crankcase while guiding the pistons into the cylinders. Position the bearing caps to crankcase and aling crankshaft with bearing caps; then tap caps into place and secure caps to crankcase. Crankshaft end-play should be checked with a dial indicator as follows, place pressure on front end of crankshaft to seat cone of rear bearings in its cup. Set indicator on high spot of crankshaft and adjust indicator to zero. Remove pressure from front end of crankshaft and reverse the procedure by placing pressure on rear end of shaft to seat cone of front bearing in its cup, then read indicator. End play should not be less than 0,08 mm not more than 0,15 mm. If end play does not fall within these limits, remove one of the bearing caps and add or remove gaskets to compensate and bring end play within the accepted tolerance. Install gasket, top plate and oil level switch to pump. Install diaphragms and add oil as instructed (see appendix for recommended oil Reconnect pump. After starting plant, inspect for leaks and tighten if necessary. Watch plant carefully for the first few hours of operation to be sure pump is maintai ning a fully charged system. Ce weiesee.6.1.5 HAPTER 6 : le COMPONENT mamrenan WATERPUMP OIL LEVEL SWITCH (see fig 6.4) a) Operation The switch actuating points should be set approxemately 20 mm above and below normal oil level to secure the pump. In normal operating conditions, the switch level arm should be in horizontal position, b) Adjustment = Disconnect main electrical power - Remove the housing cover Manuallly move lever arm up and down and check actuation by listening for switch “clicking” sounds. ~ Adjust switch actuating points by looseing both mounting screws and move bottom of switch to the right to increase actuating limits, or to the left to decrease actui limits. - After adjustment, tighten mounting screws and recheck switch actuation. | CAUTION: Bo not ad a ae Sed | 1. Housing cover 2. Oil level switch 3. Top mounting screw 4, Switch extension arm 5. Lever arm 6. Housing 7. Cover waterpump 8. Bottom mounting screw 9. Calibration mark 0. Arm position with correct oil level 11. Calibration mark. 12. Float Fig 6.4 : Waterpump oil level switch -6.7- renterOMPONENT MA in TENA mn CE” 6.1.6 WATERPUMP RELIEF VALVE (see fig 6.5) Adjusting screw Locknut Housing Spring washer Spring Stem, Guide Disc Seat Body Peenogpena Fig 6.5 : Waterpump relief valve a) Adjustment The relief valve should be adjusted to open at 35 bar feed pressure but remain drip tight during operation. Leakage from this valve will result in insufficient water to the heating unit and cause overheating renen an ache Hebi eed peer fled ee “pressure wi iaiter the unt | wee ae ~ Start plant without burner operation and slowly close coil feed valve until relief valve just begins to discharge and check pressure on feed pressure gauge at that point. - To raise pressure adjustment, turn adjusting screw clockwise; to lower pressure adjustment, turn screw counterclockwise. Secure adjustment screw with locknut after adjustment. ~ Fully open coil feed valve. Inspect relief valve for leakage during normal operation. -6.8- verneeeb) Repair + Loosen adjusting screw (1) and unscrew housing (3) form body (10). Inspect disc (8) and seat (9) for scored or damaged condition. Replace damaged seat. + If disc is scored, it may be resurfaced by rubbing it on a “figure 8" motion on a piece of fine sandpaper (wet-or- dry Nr 400 or finer) placed on plate glassrubbing it on a piece of fine sandpaper placed on a perfectly flat surface - When reassembling, make sure that the spring washers are not cocked in the housing. 6.1.7 WATERPUMP DISCHARGE SNUBBER Rubber insert type (see figure 6.6). This type is non-adjustable. If replacement of the rubber insert is necessary, the old insert must be cut away from the retainer (2). To facilitate assembly, lubricate the new insert with glycerin (do not use oil) to allow it to be pushed into the retainer and bottom housing, Top housing Insert retainer Rubber insert Bottom housing PeNe Fig 6.6 : Waterpump discharge snubber 6.2 REMOVAL OF SCALE FROM RESTRICTED HEATING COIL Consult specialized company. 6.3 REMOVAL OF EXCESSIVE SOOT FROM HEATING COIL When the exhaust gas boiler has been operated for any period of time of where uniform periodical soot blowing has not been followed, it may be necessary to wash the coil with water to remove the excessive soot accumulation. - If the exhaust gas boiler has been in operation immediately before preparing to wesh the coil, allow to cool the unit completely before the washing is started -6.9- oases,Open the inspection plate on the top cone (if provided). Provide a drain for the washing water so that no washing weter is allowed to return to the engine. Use 2 hose which can supply water at a minimum of 465 | per minute and insert the discharge of the hose (no nozzle) through the stack opening. Move the hose discharge to direct the water evenly over the entire top surface of the coil. + Soot removal will be obvious by the dark color of the water draining, When water runs clear, it will indicate that the soot has been removed, + After washing, the exhaust gas boiler can be put in operation. Se eae ee eer tearpapanronurere eoeeeee local rules) do not allow that the | na ithe sewer ase verify | -6.10- wenenes-ER-1058_E.RA Recommended oils for Clayton pumps rereKee=R10S8_E.RA a RECOMMENDED OILS FOR - Page 1 - GENERAL APPLICABLE RULES ‘TYPE OF CRANKSHAFT DRIVE - Pinion/ Gear Pinion/ Gear Belt, (1) 098422 (2) 095423 (3) 098427 B2 F2/F4 32/34 SHELL TELLUS SHELL OMALA PUMP TYPE R 150 s 100 220 “cLAY TON WATERPUMPS MIN. REV. CRANK SHAFT (RPM) as 250 250 250 250 250 250 RECOMMENDED OILS FOR CLAYTON WATERPUMPS or. CLAYTON PART NR. 098422 (1) 095422 (1) 095427 (3) 095423 (2) 098423 (2) 095423 (2)ER10S@_E.RA - Page 2 - RECOMMENDED OILS FOR CLAYTON WATERPUMPS. RECOMMENDED OILS FOR “CLAY TON“ WATERPUMPS (B) APPLICATION OF GENERAL RULES RESULTS IN FOLLOWING ‘RECOMMENDED OIL FOR CLAYTON WALERPUMPS TABLE ua26801 B-2-33 095422: 095422 : 098422 - uH26711 F-2-60 095423: 095427 : 095427 095427 vu26712, F-2-60 095423: 095423 : 095427 095427 1: UH26714 371: F+2-100 095423 : 095427 : 098427 098427 uH26715, 450 F-2-100 095423: 095423 : 095427 095427 uH26732,«: ~=—«480 F+2-125 095423: 095423 : 095427 098427 vu26717 3am F-2-150 098423 : 095427 : 095427 098427 vH26718 450 F-2-150 095423 : 095423 : 095427 : 095427 vw26613 an F+4-200 095423: 095427 : 095427 098427: uw26s1s: | 450: F-4-200 + 095423: 095423 : 095427 095427 : un26s23 an F-4-300 095423: 095427 : 095427 098427 175013, : «371: F+4~300 + 095423 : 095427 : 095427 095427: 178026 a7. F-4-300 095423 : 095427 : 095427 095427, 175027 371 F-4-300 095423: 095427 : 095427 095427 : UH27166 «=: «371: F-4-300 : 095423 : 095427 : 095427 095427, wa27531. an F-4-302 095423: 095427 : 095427 09sa27 = 1: UH27582««: 450 F-4-302 095423: 095423 : 095427 095427 vH27164 a7. F-4-200-E63 : 095423 : 095427 : 095427 o9saz7: 175008 =: «371: F-g-200-EG3 : 095423 : 095427 : 095427 095427 175024 a1 Fe4-200-EG8 =: 095423 : 095427 : 095427 095427 175025: (371: F+G-200-EG3_ (095423 : 095427 : 095427 : 095427 : 175035: «371: Feg-200-EG8 + 095423 : 095427 : 095427 095427 uu26471. 450 F-4-300 095423 : 095423 : 095427 ; 095427 175028 =: 450: F-4-300 : 095423 : 095423 : 095427 : 09S427 175029: 450: F+4-300 +: 095423 : 095423 : 095427 : o9s427 5 ALL BELT oatven > = 2 32/34 2 095623 : 095423 : 095423 : 095423 Punes, .=R105@_E.RA - Page 3 - RECOMMENDED OILS FOR CLAYTON WATERPUMPS (ey o () (conta) (2) 098422. = Shell Tellus R 150 (2) 095423 = Shell Tellus 5 100 (2) 095427. = shell mala 220 (4) In case frequency controlled motors are applied, always use the oil as prescribed under column ~ Frequency controlled - (5) Por 3-2 and J-4 pumps : always use Shell Tellus $ 100 oil. OTL CONTENT OF CRANKCASE Pump type O11 content (note 1) in litres Note 1: these are ordering quantities. To fill up crankcase, please follow instructions on pump. SUBSTITUTES FOR RECOMMENDED OILS Recommended oils (see (8) } can be substituted by oils of other make. Since Oil Companies change product names from country to country, it is advisible to contact your local oil dealer JN/ac/250891 Enclosed: ~—-Specification sheet shell Tellus Oils - Specification sheet Snell Omala Oils