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DIVISION C

BOILER MOUNTINGS
VOLUME C1
SOOT BLOWERS
LIST OF CONTENTS

Location Description Ref. No. / Drg. No

TAB-1 SOOT BLOWERS


(1-4)
LRD IIE Views 1-00-076-60569
Wall Deslagger Views (WB IE) 2-00-076-60990
Temperature Probe Views 2-00-076-61000
Soot Blower Arrangement 3-00-076-60319

TAB-2 Soot Blower Operations Emergency Check List Pub.No.7515


(5-18)

TAB-3 AC Induction Motor (For Soot Blowers) Pub.No.7506


(19-36)

TAB- 4 Soot Blower General Instructions Pub.No.7501


(37-63)

TAB- 5 Wall Deslagger Model – WB IE Pub.No.7503


(64-91)

TAB-6 Furnace Temperature Probe Model FTP IE & IIE Pub.No.7505


(92-131)

TAB-7 LRD IIE Long Retractable Soot Blower Pub.No.7514


(132-193)

TAB- 8 Methods & Procedures for Installation Soot Blowers Pub. No.7508
(194-268)

TAB-9 Soot Blower Data 4-00-076-60831


(269)

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INSTRUCTION MANUAL

SOOT BLOWER OPERATIONS


EMERGENCY CHECK LIST

Bharat Heavy Electricals Limited


Tiruchirapalli

PUB. NO. 7515


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CONTENTS
INTRODUCTION
SOOT BLOWER OPERATION -EMERGENCY CHECK LIST
SOOT BLOWER JAMMING
BLOWER MOTOR OVERLOAD
SOOTBLOWER OVERRUN
STEAM PRESSURE LOW
STEAM TEMPERATURE LOW
STEAM NO FLOW
A. C. CONTROL SUPPLY/ POWER SUPPLY FAILURE
SOOT BLOWER SEQUENCE INTERRUPTION
VALVE MOTOR OVERLOAD
PHILOSOPHY OF JAMMING RELAY PROTECTION AND OVERLOAD RELAY
PROTECTION IN SOOTBLOWER MCC.

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INTRODUCTION

This manual deals with the emergency actions that are to be carried out when an annunciation
occurs during Sootblower operation. Even though many protections are available in the sootblower
control panel, sometimes it is likely mal-operation can happen. At that time the operating and
maintenance engineers may be in search of correct course of action. We hope this manual will help
the operating and maintenance engineers to know what safe action they can take to protect the
sootblowers as well as the boiler tubes.

The contents of the manual has been carefully prepared. However, it must be understood that no
amount of written instructions will replace intelligent thinking and alertness on the part of the operator
during an emergency to reason the causes of mal-f unctions and to take ‘immediate remedial actions
demanded by the situation.

Suggestions for the improvement of the manual would be welcome.

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SOOT BLOWER OPERATION -EMERGENCY CHECK LIST

The control panel is normally supplied with the following audible and visual annunciations.

S 1. Type of
D escription of annunciation
N o. annunciation
1. S ootblow er jam m ing audible/visual
2. S ootblow er m otor overload audible/visual
3. S ootblow er overrun audible/visual
4. S team pressure low audible/visual
5. S team tem perature low audible/visual
6. S team no flow audible/visual
7. A .C . control supply failure audible/visual
S ootblow er sequence
8. audible/visual
com pletion.
9. V alve M otor overload audible/visual
10. S equence interruption audible/visual

The above alarms can be actuated during the operation of (a) long retractable soot blower (b) wall
deslagger (c) rotary blower (d), half retractable soot blower and (e) airheater cleaner (retractable).
The possible causes and solutions for each of annunciations for long retractable Soot blowers &
wall deslaggers are described in this manual. For other blowers, the causes and solutions may be
more or less similar to long retractable soot blowers.

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1. SOOT BLOWER JAMMING

This alarm will be actuated when soot blower gets jammed mechanically in the forward direction.
The alarm is given through an instantaneous overload relay which is actuated instantaneously and
will reverse the blower to bring to the home position. The instantaneous overload relay will actuate
the timer which will be set at 2 secs., normally current will be 105 percent of the rated current.

1.1 Long retractable soot blower Probable causes and solutions for jamming

Sl. No. Probable Causes Solution


(i) Lance tube fouling with the boiler During shut down the boiler tubes should be
tubes or wall sleeve rectified so that a gap of 100-150 mm is kept
in between the lance tube OD and the boiler
tube OD. Realign any tube obstructing the
lance movement.
(ii) Physical obstruction for the travelling Check the blower for proper clearance for the
carriage in the housing travelling carriage. This can be checked only
by local operation

(iii) If direction of rotation for traverse Change the power cable loads with power off
motor is incorrect and run blower again.
(iv) Failure of reverse limit switch Replace the defective switch
(v) Valve stem jammed/pitted Remove the stem and replace or rectify
(vi) Overtightened gland packing in Loosen the gland
travelling carriage

1.2 Wall Deslagger : Probable Causes and Solutions for Jamming:


(i) Swivel tube fouling with shroud Position the blower in such a way that the
tube swivel tube does not foul with the shroud
tube and the perpendicularityto the water
wall is to be maintained.
(ii) Dust accumulation on the guide Clean the guide rods and the swivel tube
rods and the swivel tube once in a week. If the accumulation of dust is
severe, and morefrequent provide additional
covers.
(iii) Direction of traverse motor is in- Change the direction of motor by
correct changing powerleads.
(iv) Wrong setting of limit switches Reset the Cam.
LSTS and LSTE
(v) Too much of Gland tightness Loosen the gland nuts to have enough
on wall blower body. freeness.
(vi) Valve stem/pitted jammed Remove the item and replace or
rectify.
'Reset'push button on the panel should be pressed to continue the sequentialoperation after
bypassing the faulty blower.

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2. SOOT BLOWER MOTOR OVERLOAD

This annunciation will come on as soon as the motor gets overloaded the traverse motor will get
stopped. The thermal overload relay is set to act normally when the current exceeds 105 percent of the
rated current. The probable causes and solutions for his are given below :

2.1 Long retractable soot blower - Motor overload- Probable Causes and Solutions :

Sl. No. Causes Solutions


(i) Lance tube fouling with boiler Same solution as indicated under
tubes sootblower jamming.
(ii) Overtightened gland packing Do not overtighten the glands. A
slight leakage of steam is allowed.
(iii) Wrong overload relay setting Check the overload relay setting and
set the relay at the correct value.
(iv) Dust accumulation over the rails Clear the dust and debris.
(v) Wrong motor installation in Check the overload relay setting and
powerpacks. set the relay at the correct value.
(vi) Damaged power/control cables Check the power cables. It is likely
(Short circuit in any two phases in that cables damage will result in
M.C.C. or Terminal box) short-circuiting.
(a) Check the power cable from
MCC. to blower terminal box.
(b) Check the power cable from the
motor to terminal box.
(c) Check the terminal box of motor.
(vii) Motor winding fault Refer the motor instructions manual.
2.2 Wall deslagger:
(i) Swivel tube fouling with the boiler Same solution as indicated under
tubes ‘Sootblower jamming’.
(ii) Wrong overload relay setting Do as suggested in 2. 1. (iii)
(iii) Short circuit in the powerloads in Do as suggested in 2.1 (vi)
M.C.C. or in terminal box
(iv) Motor winding fault Do as suggested in 2.1 (vii)
(v) The rack comes out of pinion Sometimes because of loose screws
of cams the rotary gear box is
likely to come out of pinion. For this
(a) an easy solution would be to put
two rubber washers on guide rods.
(b) Periodically tighten the cam screws.
(vi) Improper meshing of gears Dismantle the gear box and check
the meshing of gears.
Overload relay should be reset in M.C.C. before operating the same blower. After ensuring
the lance of the particular blower is withdrawn to the home position only, the
sequential operation should be continued. Physical checking is a must.

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3. SOOTBLOWER OVERRUN
The total time for forward and reverse operation of sootblowers is supervised by elapsed timers.
When the blower stays for a longer time than its normal working time the blower overrun annunciation
will come and will stop automatic sequence operation and at the same time retract the blowers to its
initial position. Normally the timer is set in excess by 1 or 2 minutes of blower operating time.
The probable causes and suggested solutions are given below
3.1 Long Retractable Soot blower-Soot blower overrun-Probable causes and solutions

Sl. No. Causes Solutions


(i) Faulty reverse limit switch If the blower is not withdrawn auto-matically
Immediate action
Allow the steam flow if the blower is located in hot
zone. Send one man for closing the regulating valve
manually. Switch off the power,
Then withdraw the lance manually.
Caution
Do not allow the lance inside the boiler for a longer
time with blowing medium.
Later
Check the limit switch contacts, spring, etc. If it is
in serviceable condition service and put back the
switch. If it is not possible then replace the switch
with a new one.

(ii) Wrong timer setting Normally the timer is set more than 1 minute than
the operating time. Check the timer setting and set
correctly.
(iii) Failure of contactor and Check the forward and reverse contactor, clean the
contactor reverse (CR) coils terminals and' contacts and put back in M.C.C.
(iv) Traverse chain failure due to Immediate action :
the weak link (a) Allow the steam flow not more than 5 minutes.
(b) Wrap a chain or rope around the travelling
carriage through a winch. If this takes too much
of time, stop the steam flow. By doing so it is
likely that the lance may get bent. In case of
blowers located in low temperature zones, the
steam flow can be cut off just after the jamming has
occurred
(c) And now stop the steam flow.
(d) Pull out the lance tube.
Later : Replace the damaged chain link,
using connector link.
(v) Traverse Motor shaft breakage Immediate Action :
(a) Cut off power supply.
(b) Allow the steam flow for not more than 5 minutes.
(c) Retract the lance, using the hand crank.
Later
Assemble a new motor and check the direction of
rotation before the blower is put into operation again.
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Sl. No. Causes Solutions


(vi) Burnt out or damaged traverse Immediate Action :
Motors. (a) Cut off the power supply.
(b) Allow the steam flow for not more than 5
minutes.
(c) Retract the lance tube using the hand crank,
after cutting off steam supply.
Later
Assemble a new motor or repaired one and check
the direction of rotations before the blower is put
into operation again.
(vii) Thermal overload Immediate Action
Relay for traverse (a) Cut oft the power supply.
motor blows as a (b) Allow the steam flow for
result of which not more than 5 minutes.
the traverse motor (c) Retract the lance tube using the hand
stops. crank as suggested in 3.1.(i)
Later
Check why the motor has stalled.
Find out the cause

3.2 Wall Deslagger:


Immediate Action:
(i) ‘ LSTR ' limit switch fails to (a) Switch off the power supply.
operate or damaged, missing switch (b) Using the hand crank, withdraw the swivel
arm. tube. (Hand cranking is possible with steam
on).

(ii) Wrong timer setting Normally the time is set for 120 secs. Check thetimer
setting and set correctly.
(iii) Faulty rotary contactor (CRO) Check the rotary contactor, clean the terminals and
contacts and put back in M.C.C.
(iv) Failure of Traverse motor -shaft Immediate Action
or rotary motor shaft (a) Switch off the power supply.
(b) Using the hand crank withdraw the swivel
tube. (Withdrawl of swivel tube by hand cranking
is possible with steam on)
Later :
Assemble a new motor and check the direction of
rotation before ,he blower is put into operation again

(v) Burnt Out or damaged motors Immediate Action :


(a) Cut off the power supply.
(b) Retract the swivel tube using the hand crank.
Later :
Assemble new motors and 'check the direction of
rotation before the blower is put into operation again.
Reset push button on the panel should be pressed to continue the sequential operation after
ensuring the particular blower is in home position. Physical checking is a must.

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4. STEAM PRESSURE LOW

This annunciation will come to the operator as soon as the system pressure is lower than the set
value. As soon as the annunciation is received, retract the blower immediately and stop the
sootblowing operation. The probable causes and suggested solutions are as follows:

S1. No. Probable Causes Suggested Solutions


(i) Multiple leaks in the system Stop the sootblower operation.
(a) sootblower valve passing. Later
(b) Sootblower flange leakage. Identify the leakage in the system
(c) Drain valve heavy leakage. and attend the leaks.
(ii) Mal-functioning of pressure reducing Immediate Action:
valve Stop the sootblower operation.
Later :
Attend to this problem. Ref.detailed
instructions for trouble shooting
of pressure reducing valve.
Immediate :
(iii) Hand stop valve partially closed (a) Stop the sootblower operation
(b) Open the valve fully.

(c) Then proceed with SB operation.


(iv) Erratic action of pressure switch or Immediate Action:
damaged pressure switch. Sootblowing can be continued
by watching the pressure indicator
available on the panel.
Later :
Attend to pressure switch or
replace with a new one.
CAUTION :
Close the steam supply before
attending the work.
(v) Broken supply line Immediate :
Stop the sootblower operation.
Later :
Close the steam supply.
Repair the failed steam piping.
Then proceed with Sootblower
operation.
‘Reset’ push button on the panel should be pressed to continue the sequential operation. Physical
checking is a must wherever necessary.

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5. STEAM TEMPERATURE LOW

This annunciation is provided so that the operator will be cautioned when the medium temperature
is low. It is likely that low steam temperature will cause condensation which will lead to boiler tube
wastage. This may be due to inadequate ‘warm up’ and poor insulation. The solutions will be
sufficiently warm up the line and ensure sound insulation.
Another cause may be choking in the drain line. The solution would be to remove the condensate
properly.
‘Reset’ push button should be pressed after rectifying the fault to continue the sequential operation
further.

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6. STEAM NO FLOW
During the operation of the blower, if steam supply is interrupted for a longer time than the set time
in the timer, then the annunciation will come, stop the sequence and retract the lance to the home
position.
‘Steam no flow’ interlock was caused by failure to turn on the blowing medium approximately 45
secs after a signal was sent to sootblowers.
The probable causes and solutions are as follows :
Sl. No. Probable causes Solutions
6.1 Long retractable sootblower.
(i) Missing blowing adjustment bar orAs soon as the alarm is initiated check whether the
broken adjustment bar. blower lance is retracted back to the home position
bypass the blower and proceed with sequential
operation.
Later :
Assemble the blowing adjustment bar.
(ii) Mal-adjusted or damaged flow switch If adjustment is to be corrected, correct the switch. If
(common for wall deslagger) you have found that the switch is damaged then
attend to the damage. If it requires longer time
proceed with the sootblower operation bypassing the
inter-lock. But this can be done only if one or two
men are kept near the blower.
(iii) An improper setting in the timer Adjust the timer to initiate annunciation after 45 sees.
(common for wall deslagger)
(iv) Valve not opening due to Immediate
(applicable for wall deslagger) If the blower is retracted back then bypass the blower
and proceed with, sequential operation..
(a) missing and damaged pins of valve
opening mechanism Later
Check the pins. If any pins have damaged replace
(b) Mal-operation of valve them. Check the lever engagement pull tod cam etc.
operating mechanism If it is not OK make it sleight.
(c) Overtightened gland packing Check the valve opening and closing. Make the
glands loose. Slight leakage is permissible.
d) Stem pitting Before removing the valve close the
steam supply. If the stem pitting is
severe replace with a new stem.
(e) Missing of valve opening Check the presence of screw. If
screw on lever the screw is not in position, new
screw is to be assembled.

6.2 Wall deslagger Immediate


(i) Missing ramp cam on the rack Make sure the unit is retracted back
immediately. Bypass the blower and
proceed with sequential operation.

Later :

Check physically the blower and


replace new cam.
If the blower has been retracted to the original position, bypass the blower and
press the reset button for proceeding with sootblower sequential operation.

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7. A. C. CONTROL SUPPLY/ POWER SUPPLY FAILURE


When the A.C. supply fails during the operation of blowers, an alarm is annunciated. If the sootblowing
operation is proceeding at that time, send a gang for withdrawing the blower back out of the boiler.
Proceed as follows :
7.1 Long Retractable Soot blower
(1) Send one man for closing the manual operated valve.
(2) Send another man with hand crank. After declutching withdraw immediately.
7.2 Wall deslagger
Send a man with a hand crank to withdraw the lance tube. “Reset” button must be pressed in the
control panel before proceeding with the operation after the power is restored.

8. SOOT BLOWER SEQUENCE INTERRUPTION

This annunciation will come to the operator when the blower does not start even after the sequencing
signal is given to the other blower to start. If the blower does not start after 10 secs. even after the
completion of operation of the previous blower then this annunciation will come. The probable
causes and solutions are as follows :

Sl. No. Probable causes Solutions


(i) Motor burnt out or damaged Immediate:
traversing motor Bypass the blower from sequence operation
Press ' reset ' button and proceed with other
blower operation.
Later :
Check the motor. If possible repair the same
or replace with a new motor.
(ii) Failure of motor starter, broken Immediate:
wires, motor overload. Bypass the blower from sequence operation
and proceed with other blower operation.
Later :
Identify the problem and rectify the system.
(iii) Defective cabling. Immediate:
Bypass the blower from sequence operation.
Press "reset" button and proceed with other
blowers operation.
Later :
Identify the problem and rectify the
system.
Press "reset" button in the panel before operation is continued.

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9. VALVE MOTOR OVERLOAD


This annunciation will come if the main supply valve actuator is overloaded. The probable causes
and solutions are as follows :

Sl. No. Probable causes Solutions


(i) Too much gland overtightening Ensure correct gland packing and
tightness.
(ii) Score marks on stem Check Recondition/ Replace stem if
necessary.
(iii) Non-release of motor brake Remove the brake mechanism and
service.
(iv) Wrong setting of limit switch on the Set the limit switches correction as
actuator. instructed in 0 & M manual.
(v) Wrong overload relay setting. Check and set overload relay at the
recommended value.
(vi) Excessive torque setting of torque Set the torque switches at the
switches. recommended value as per 0 & M
manual No. 7001.
(vii) Jamming of moving components in Bypass the whole steam line and
the guide ways. then do servicing, For detailed
repairing procedure refer the relevant
0 & M manuals.
After attending to the fault, press 'reset' button in the panel before the operation
is continued.

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10. PHILOSOPHY OF JAMMING RELAY PROTECTION AND OVERLOAD RELAY


PROTECTION IN SOOTBLOWER MCC.

1. Overload protection is for all motors and for all blowers.


2. The setting of overload relay shall be 105% for all the motors for all types of blowers. All
motors in all types of blowers have 110% capacity for 30 mts.
3. The normal loading of motors in all the blowers when the blower is working with steam is
likely to be around 50%.
4. The overloading of motor in LR blowers is expected due to hitting of tubes etc.
5. The overload relay which is set at 105% when about 300% current (starting current) is
flowing will act in about 25/30 secs. (When the relay is hot/ cold).
6. Jamming relay protection is only for long retractable type blowers. The jamming relay
shall be connected in Traverse Motor power line. Jamming relay will act instantaneously.
7. The current setting of the jamming relay shall be 105% of traverse motor rated current.
8. A time delay relay (0-10 secs.) is provided in Jamming relay protection circuit and is set
at 2 secs. This is to avoid the nuisance which may arise due to action of Jamming relay
7during the starting of traverse motor. The starting time of traverse motor is 0.3 sec. The
starting current of traverse motor is 3.0 Amps.
9. Jamming relay with its circuitry will act when overloaded to 105% due to overload/
jamming while on forward operation and reverse the blower. Overload relay will act when
overloaded to 105% while on traverse operation. The blower stops operating. However
the motor is protected.
10. Locked rotor withstand time for traverse motor is 40 secs. in hot and 75 secs. in cold
conditions.
11. Selection of jamming relay and C.T.
CAG 19 English Electric Relay with 5 Amps. operating coil and 20-80%setting range.
5/5A ratio C.T. 5P20, 15VA

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TAB - 3

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INSTRUCTION MANUAL
AC INDUCTION MOTOR
(FOR SOOT BLOWERS)

Bharat Heavy Electricals Limited


Tiruchirapalli

PUB. NO. 7506

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1216 - 1217 VOL - C1 TAB - 3 - 19
CONTENTS
GENERAL INFORMATION
GENERAL
STORAGE
LOCATION OF MOTORS AND CONTROL APPARATUS
GEAR DRIVES
DRYING OUT
REVERSAL OF ROTATION
INSPECTION AND TESTING5
GENERAL
MECHANICAL
ELECTRICAL
MAINTENANCE PROTECTION OF EXPOSED SURFACE6
GENERAL
INSULATION RESISTANCE
REMOVAL AND REPLACEMENT OF BEARINGS
BALL AND ROLLER BEARINGS
LUBRICATION
CONTROLLERS, STARTERS AND RHEOSTATS
SAFETY DEVICES
CHECK CHART
AC MOTOR CHECK CHART
MAINTENANCE SCHEDULE1
LIMITS OF TEMPERATURE RISE
DATA SHEET FOR SOOT BLOWER MOTORS

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GENERAL INFORMATION
1.1 GENERAL
Where the magnitude of the installation justifies the cost, a set of record plans should be provided
by the installation engineer or contractor, clearly indicating the complete layout of the installation.
There is always the possibility that hair, hands or clothing may be caught in moving parts of
electrical machines, which should thus be so located or guarded as to minimize the risk of such
injuries to those who may come in contact. In the case of equipment subject to the provisions of
the Factories Act such mechanical protection is a statutory requirement.
1.2 STORAGE
If the machine has got to be stored for some time before installation, the same has to be done in
a clean, dry place. If the location is susceptible for vibrations transmitted due to working of
heavy machinery, proximity to rail track, etc. it is desirable to have a resilient pad between the
floor and the machine. Also keep the shaft of the motor locked so that, bearings are not damaged
during storage. However, periodically rotate the shaft free and relock it.
1.3 LOCATION OF MOTORS AND CONTROL APPARATUS
Apparatus shall be so located that all current-carrying parts are adequately ventilated in relation
to the losses to be dissipated in the form of heat.
Note: In no circumstances should the motor be enclosed in a box or other covering hat restricts
or excludes the ventilating air to a significant extent. Such restriction may result in the
burning out of the motor when a sustained load approaching the full value is reached.
The motor and control apparatus shall not be located where it is liable to exposure to water,
corrosive liquid, oil, steam, carbon, copper dust, dirt or other adverse condition or to risk of
mechanical damage, unless it is suitably enclosed to withstand such conditions.
Adequate access shall be provided to all working parts. The possible need for facilities for
removing the equipment at a later date for repairs or maintenance should be considered in relation
to the accessibility of the equipment.
Note: For handling heavy equipment it is often advisable to arrange for the incorporation of a
lifting beam in the structure of the building, the beam being located immediately over
such parts of the equipment as may require attention and being capable of supporting
the maximum weight involved.
The placing of apparatus in situations where inflammable material may be present should be
decided in relation to the fire risk involved, and where it is impracticable to segregate the apparatus
from such material, the use of totally enclosed or pipe ventilated apparatus should be considered.
Where resistors are used which are liable to operate at high temperatures, they should be adequately
spaced away from combustible materials such as wood-work, in order to combat the risk of fire.
Whenever the temperature of the casing of the apparatus is liable to exceed 194 Deg. F (or 90
Deg.C) the casing should be so located or guarded as to prevent accidental contact by persons or
with combustible materials.
1.4 GEAR DRIVES
With gear drives, alignment is equally important. The centre of the pinion shall be in line with
the centre of the spur wheel and the two wheels perfectly parallel, the latter being checked by
means of feeler gauges between the teeth of the respective wheels. The gear wheels shall be fully
meshed both in depth and along their width of face and the check for meshing shall be made all
the way round the driven wheel in case it is out of truth. Should the driven wheel be out of truth
and the meshing adjusted correctly at the lowest point of the driven wheel, the gears would jam
when the high parts engage and probably bend the motor shaft.
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Bevel or single helical gears will impose an end thrust on the motor shaft, and are not therefore
recommended unless provision is made to take the thrust. Double helical gears may also transmit
an end thrust if the end-play in the bearings of the driven gear is greater than the end-play in the
motor bearings. Where mechanical conditions are severe it is sometimes necessary, particularly
in the case of large motors, to employ an outboard bearing for the motor shaft and in some cases
to mount the driving pinion in two separate bearings and couple it to the motor through a suitable
flexible coupling. A flexible coupling is invariably necessary when a motor is coupled to a self-
contained gear box. It is advisable, when any drives of the above mentioned or similar types are
considered, that this be specified so that provision can be made to suit the conditions.
Where motors are fitted with ball and roller bearings, care shall be taken to ensure that no axial
strain is imposed on the bearings when the half-couplings are bolted together.
1.5 DRYING OUT
All motors shall be dried out before the full voltage is applied to the terminals, if the insulation
resistance is below one megaohm when the machine is cold. A convenient method of doing this
is to block the motor so that it can not rotate and apply a very low voltage of about 10 percent of
the normal to the stator terminals.
In the case of slip-ring motors, the rotor windings should be short-circuited.
Close supervison is necessary during the process of drying out with this method. The heat
generated in the windings is not easily dissipated and one part of the winding may be exceeedingly
hot before another part has had time to expel the moisture. This may be obviated to some extent
by taking every precaution to exclude draughts from the exposed parts of the windings.
The motor can be placed in oven, if available, but the temperature shall not be allowed to exceed
180 Deg. F (or 82.2 Deg.C). Alternatively, hot air may be blown into the motor but the air should
be clean and dry and at a temperature of not more than 180 Deg.F. If no other means are available,
coke braziers or electric radiators may be placed round the machine. Carbon filament lamps
placed inside the machine can be employed quite satisfactorily, but care shall be taken that the
hot bulb is not in contact with any windings. If it is not possible to reach a sufficiently high
temperature the ventilation may be reduced by covering the stator with a tarpaulin.
Whichever of the above methods of drying out is adopted, the heating shall be continuous and
shall be carefully watched to ensure that it does not attain a temperature sufficiently high to
damage the insulation. The maximum safe temperature of the windings measured by thermometer
is 180 Deg. F (or 82.2 Deg.C). At the same time the temperature should not be allowed to fall too
low as otherwise re-absorption of moisture would take place.
The insulation resistance will be found to drop considerably as the motor warms up, will reach
the minimum and then remain constant for sometime depending upon the dampness of the machine
and as the drying proceeds the insulation resistance will gradually rise. The drying out shall be
continued as long as the insulation resistance rises, or until a sufficiently high value has been
reached, i.e. not less than 1 megaohm per 1000 volts at 75 Deg.C.
During the drying out period, readings of temperature and insulation resistance shall be taken
atleast once an hour in order to see how the drying out is progressing. The temperature of the
motor shall be kept as constant as possible, otherwise the insulation resistance readings may be
misleading.
NOTE: The motor should be watched constantly whilst drying out.
1.6 REVERSAL OF ROTATION
Reversal of rotation, if required shall be effected by interchanging two of the three supply leads
connected to the stator switch, breaker or starter.

4
GO TO INDEX
1216 - 1217 VOL - C1 TAB - 3 - 22
2. INSPECTION AND TESTING
2.1 GENERAL
All electrical equipment shall be inspected and tested by competent persons at regular intervals,
the frequency of such inspection depending on the type of equipment and on the operating
conditions. A record of each inspection and of the result of tests should be kept.
2.2 MECHANICAL
Machines shall be checked for alignment to ensure that undue stresses are not imposed on their
bearings.
Where oil-lubricated bearings are employed care should be taken to see that oil does not penetrate
on to windings or other insulation. In addition clearances shall be kept to reasonably close limits
as too large a clearance may affect correct alingment and may cause fouling of the stator by the
rotor, whilst too small a clearance may disturb running mechanical balance. Oil should be checked
to see that it is clean and up to the right level.
The air gaps in sleeve bearing machines shll be checked before commissioning. This check
should be repeated at periodic intervals.
Mechanical operation of motors control gear and protective devices shall be checked for freedom
from external material, care being taken when commissioning to see that all packing materials
are removed.
In the case of motors and control gear, attention should be paid to all contacts, the contact pressure
and contact area being checked and verified as being proper to the operating conditions involved.
If ball roller bearing motors have been kept idle for periods longer than six months whether new,
spare or stand-by plant, the bearing covers should be removed for inspection of grease. If it is
found that the grease has a skin over the surface, the bearings should be washed out thoroughly
in kerosene, and three drops of fine oil added to the race. The bearing housings should be
repacked with new grease recommended by the makers, care being taken to ensure that the balls
or rollers will not churn in the grease. One of the chief functions of grease is to prevent the entry
of dust to the races, very little being required for lubrication.
2.3 ELECTRICAL
All fixed connections shall be checked for tightness and where heavy currents are involved a
check shall be made to see that contact adequate in area and pressure to prevent undue heating is
effected between all contact surfaces.
Before the equipment is put into service, it shall be tested for insulation resistance and other tests
as may be necessary should be made. Continuity tests shall be carried out, particular attention
being given to the secondary connections of current transformers. Before switching in for the
first time, protective devices shall be set at their minimum current values and at the minimum
time setting in order to minimise the consequence of any fault condition which may arise.
The rating of fuses shall be checked by inspecting the marking on the cartridge-type fuses or
inspecting the gauge and type of wire in the case of semi-enclosed type-fuses. Where practicable,
the operation of overload, no volt and other types of protective device shall also be checked. The
results of such checking should be related to the ascertained resistance of the earth-fault current
path so as to determine the prospect of the protective device operating in the event of a fault to
earth. Earth leakage protection should be adopted in the following cases:
a. If the ascertained resistance is such as to restrict the fault current to a value below the
operating value of the overload releases.
b. If the margin is too small to ensure reliability in all seasons.

5
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1216 - 1217 VOL - C1 TAB - 3 - 23
c. If, where fuses are used, the resistance is such that sufficiently rapid operation cannot
be ensured, and the earthing conditions cannot be improved.
Protective fuses shall be examined regularly, and, as far as possible tested. Where relays are used
in conjunction with current transformers, the test should preferably stimulate working conditions
by utilizing the injection method whereby current is passed through the relays by the application
of a variable injection voltage from a transformer designed for the purpose.
3. MAINTENANCE PROTECTION OF EXPOSED SURFACE
3.1 GENERAL
Protective paint and varnish shall be maintained in good condition by repainting or revarnishing
when necessary, it being noted that in many instances, such as that of machine windings, spraying
is the only effective means of application of such protection.
MOTOR
Cleaning of Machines
Motor shall be blown out at regular intervals to keep their ventilating passage clear, it being
emphasised that many types of totally enclosed motors required such attention, particularly when
operating in dusty atmosphere.
Moisture, oil, dirt, grease and carbon or metallic dust are the principal causes of breakdown. The
motor should therefore be kept clean and dry; water dropped on the machine will soon cause
trouble, unless the motor has been designed to withstand such conditions. The stator and rotor
windings must be kept free from oil and grease, damp and dirt. Periodic cleaning with dry
compressed air, bellows or a brush, is very necessary.
All motors require to be examined and dismantled from time to time and the frequency of
successive cleanings will depend upon the conditions under which the machine operates. During
periodic cleanings care shall be taken to clear air passages in the stator and rotor of any accumulated
dirt.
Terminals and screw connections shall be kept clean and tight. If they become dirty or corroded,
they shall be disconnected and all contact surfaces made clean and smooth. Bad contact leads to
sparking and ultimate breakdown.
After reassembly, the gaps shall be tested as a precautionary measure by means of a feeler gauge.
If it is found that the air gap measurements of two diametrically opposite points differ by as
much as 25% the machine shall be examined, because the brackets or bearing housings will not
be correctly aligned. Gap measurements shall always follow reassembly, since rubbing between
stator and rotor will cause extensive damage.
3.2 INSULATION RESISTANCE
The insulation resistance of the windings shall be tested periodically during service and where
this is found to drop below 1 megaohm/KV with a minimum of 1 Megohm the motor shall be
dried out and put in service. If weak insulation, resistance becomes a regular feature the windings
shall be given a coat of good insulating varnish after the machine has been dried out. Where the
motor is installed in locations, subject to dampness, chemical fumes, etc., the installation indicator
such as a neon lamp to show the condition of the insulation of the motors is recommended.
3.3 REMOVAL AND REPLACEMENT OF BEARINGS
In small frame motors, the bearings can be removed with a bearing puller. The cartridge type
bearing housing is employed in large frame motors.
After cleaning, the housing should be greased with the specified grade grease and the bearing
replaced by applying even pressure to the outer race. Having ensured that the bearing is square
with the housing, it may be necessary to tap lightly into position.
6
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1216 - 1217 VOL - C1 TAB - 3 - 24
Having ascertained that the outer race beds firmly against the housing shoulder, the whole may
be slipped over the shaft which should be cleaned and oiled.
The bearing may now be forced on to the seating by means of a tube placed over the shaft and
applied to its inner race; this method ensures even pressure and the bearing may be driven home
against its locating shoulder. On no account must the inner race mounted by hitting the outer
race and pressure should not be applied to the outer race during the process. The blows should
be equally distributed all round the inner race and care should be taken to avoid hitting or applying
pressure to the lip of the inner race, in the case of a roller bearing. Otherwise the bearing along
with the bearing housing can be heated in medium oil Shell Tellus – 33 Deg. at a temperature not
exceeding 100 Deg. C for about one hour to enable easy mounting by push fit.
3.4 BALL AND ROLLER BEARINGS
Climatic conditions affect the lubrication and it is necessary to ensure that the bearings do not
run hot. This shall be tested from time to time by placing the hand on the bearing cap. A
moderate warmth to the hand is a ready indication that the bearing is running at its best. Higher
or lower temperatures are not dangerous in themselves but increasing temperature or noise are
sure signs that the bearing needs immediate attention. It may be that the addition of a small
amount of grease will arrest and cure the trouble.
When opening up bearings for inspection and cleaning, all dirt and foreign matter shall be removed
from the neighbourhood of the bearing caps. The caps shall then be removed and the bearings,
caps and housings washed with kerosene, all old grease also being removed in the process and
the parts thoroughly cleaned. If the bearing is in good condition, fresh grease shall be pressed
well between the cage, races, balls and rollers. We recommend Shell Alvania No.3 grease or it’s
equivalent. After packing the bearing, any superfluous grease shall be wiped off. If the bearing
appears dirty or if the grease has become hard and disintegrated the bearing shall be removed
from the shaft, withdrawn from the housings and closely inspected for signs of wear.
3.5 LUBRICATION
It is often assumed that with the substitution of rolling motion for sliding motion in antifriction
bearings, the sources of friction are eliminated and lubrication is of secondary importance. But
this is not correct since sliding friction still occurs at the cage which separates the rolling elements
or between the element themselves if they are not separated.
The smooth and silent running of antifriction bearings depends to a large extent on the high
degree of finish imparted to the tracks and rolling elements, and quite apart from its function of
minimising wear on rubbing surfaces, the lubricant is required to protect these highly finished
working parts. The rolling element bearings require a small amount of lubricant depending upon
the size and type of bearing and generally the lubricating intervals are long. However, lubricant
must always be present in the bearings otherwise their lift may be affected or retarded by injuries
which could have easily been avoided.
The main functions of lubricant in a bearing are:
i. To provide a separating film between rolling and sliding contacting surfaces, thus pre
venting wear.
ii. To act as a coolant to maintain proper bearing temperature.
iii. To prevent the bearing from being contaminated by dirt and other foreign matter.
iv. To prevent corrosion of bearing surfaces.
When the moving parts of a bearing come in contact with grease, a small quantity of oil adheres
to the bearing surfaces. Oil is therfore removed from the grease near the rotating parts. The oil
that is picked up by the bearing is gradually broken down by oxidation, or lost by centrifugal

7
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1216 - 1217 VOL - C1 TAB - 3 - 25
TWO PART BEARING HOUSING

BALL BEARING WITHDRAWAL BALL BEARING REPLACEMENT

force, and volatalisation. Bleeding of the Grease therefore takes place to continue the supply of
a small quantity of oil, which is usually sufficient for satisfactory operation.
Lithium based Multipurpose Grease conforming to Grade 3 of IS 1002-1956 amended upto date,
is recommended for all Rotating machines fitted with antifriction bearings.
The popular greases are:
Shell Alvania (or Multipurpose) Grease 3
Mobilux Grease No.3
Castrol Shperol. AP3
The safe operating temperature range for the above greases is:
-130F to 2480F (approx. Value)
The quantity of Grease which should be applied to the inside of the bearing when relubricating
is,
D x B
W = —————— x 28.35 Grams
6000
Where D = O.D. of the Bearing in mm
B = Width of the Bearing in mm
W = Weight of grease in gm
Running conditions, especially speed relative to the bearing size determine the permissible
relubrication frequencies, provided an approved ball bearing grease is used.
Over-lubrication is equally hazardous as under-lubrication. If excess grease is maintained in the
race-track under-pressure, excessive friction develops often resulting in the break-down of the
grease, which in turn affect the life of the bearing considerably.
3.6 CONTROLLERS, STARTERS AND RHEOSTATS
The contact and insulating parts must be kept thoroughly free from dirt and moisture and there
shall be firm metallic connection between fixed and removable contacts when they come together.
The covers shall be removed periodically for inspection.
Fuse contacts and terminals must be examined periodically for cleanliness and tightness. When
a fuse wire or strip has to be renewed, care must be taken that the new is of the correct metal and
size.
8
GO TO INDEX
1216 - 1217 VOL - C1 TAB - 3 - 26
3.7 SAFETY DEVICES
Remote tripping devices and limit switches which are provided for safety reasons but which may
not be called upon to function under normal operating conditions, shall be checked for operation
at regular intervals.
Interlocks designed to prevent unsafe operations shall be checked periodically by a deliberate
attempt being made by a competent person to perform the operations which the interlocks are
designed to prevent.
Where an emergency supply is provided, the source of supply and all ancillary apparatus shall be
checked periodically.
3.8 CHECK CHART
A check chart should be kept for assistance in the maintenance of the motor. A recommended
chart is given in Section 4. All reports and test results shall be recorded in a suitable log book.

4. AC MOTOR CHECK CHART


SI.No. Trouble Cause Remedy

01 Hot Bearings - Bent or sprung shaft. Straighten or replace shaft.


General. Excessive belt pull. Decrease belt tension.
Pulley too far away. Move pulley closer to bearing.
Pulley diameter too small. Use larger pulley.
Misalignment. Correct by realignment of drive.

02 Hot Bearings Insufficient grease. Maintain proper quantity of


ball or roller. grease in bearing.

Deterioration of grease or Remove old grease, wash


lubricant contaminated. bearings thoroughly in kerosene
and replace with new grease.

Excess lubricant Reduce quantity of grease.


Bearing should not be more than
1/2 filled.

Heat from hot motor or Protect bearing reducing motor


external source. temperature.

Overloaded bearing. Check alignment, side thrust and


end thrust.
Broken ball or Rough Replace bearing; first clean
races. housing thoroughly.

03. Oil leakage from Stream of overflow plug Remove re-cement threads
overflow plugs not tight. replace and tighten.

Cracked or broken Replace the plug.


overflow plug.

Plug cover not tight. Requires cork gasket or if screw


type may be tightened.

9
GO TO INDEX
1216 - 1217 VOL - C1 TAB - 3 - 27
SI.No. Trouble Cause Remedy
04. Motor dirty Ventilation blocked end Clean motor will run 10° to 30°C
winding filled with fine cooler. Dust may be cement,
dust or lint. sawdust, rock dust , grain dust,
coal dust and the like.Dismantle entire
motor and clean all windings and
parts.
Rotor winding clogged. Clean and grind slip rings. Clean and
treat windings with good insulating
varnish.
Bearing and brackets Dust and wash with cleaning solvent.
coated inside.

05 Motor Wet Subject to dripping Wipe motor and dry by


circulating heated air
through motor.. Install drip
or canopy type covers over motor
protection.

Drenched condition. Motor should be covered to retain


heat and the rotor position
shifted frequently.

Submerged in flood Dismantle and clean parts.


water. Bake windings in oven at
180°F (82°C) for 24 hours
or until resistance to ground
is sufficient.

06. Motor stalls Wrong application. Change type or size.


Consult manufacturer.

Overloaded motor. Reduce load.

Low motor voltage. See that nameplate voltage is


maintained.

Open circuit. Fuses blown, check overload


relay, starter and pushout.

Incorrect control Check control sequence.


resistance of wound Replace broken resistors.
rotor. Repair open circuits.

Mechanical locking in Dismantle and repair.


bearings or at air gap. Clean air gap if choked.

07. Motor connected No supply Voltage. Check Voltage on each phase.


but does not start One phase open voltage
too low.

10
GO TO INDEX
1216 - 1217 VOL - C1 TAB - 3 - 28
SI.No. Trouble Cause Remedy
Motor may be over Reduce load or try to start
loaded. uncoupled from load.
Control gear defective. Examine each step of the control
gear for bad contact or open
circuit. Make sure that brushes are
making good contact with thering.
Starting torque of load If of squirrel cage type and
too high. with auto-transformer
starting change to a higher tap.

If of slip-ring type, lower


the starting resistance.
Rotor Defective. Look for broken rings.

Poor stator coil Remove end belts, locate


connection. with test lamp.

Mechanical locking in Dismantle and repair.


bearings or at air gap. Clean air gap if choked.

08. Motor runs and Power failure. Check for loose connections
then dies down. to line, to fuses and to control.
(see also SI.No.7).

Overload. Examine overload trips. See


that they are set correctly
to approximately 150 percent
full load current. See
that the dashpots are filled
with correct quantity and
grade of oil.

09 Motor does not Not applied properly. Consult supplier for proper
come upto speed. type.

Voltage too low at Use higher voltage on


motor terminals transformer terminals or
because of line drop. reduce load.

If wound rotor Correct secondary control.


improper control
operation of
secondary resistance.

Starting load too high. Check load or motor which is


supposed to carry at start.

Check that all brushes Check secondary connections


are riding on rings. Leave no loads poorly
connected.
11
GO TO INDEX
1216 - 1217 VOL - C1 TAB - 3 - 29
SI.No. Trouble Cause Remedy

Broken rotor bars. Look for cracks near the rings. A


new rotor may be required as
repairs are usually temporary.

Open primary circuit. Locate fault with testing device


and repair.

10. Motor takes too Excess loading. Reduce load. If motor is


long to accelerate driving a heavy load or is
starting up a long line of
shafting start more slowly
allowing ample time for
acceleration till it overcomes
the difficulty.

Poor circuit. Check for high resistance.


Defective squirrel Replace with new rotor.
cage rotor.

Applied voltage too Get power company to


low. increase voltage tap.

11 Wrong rotation. Wrong sequence of Reverse connections of


phases. motor or at switchboard.

12. Motor overheats Check for overload. Reduce load.


while running
underload. Wrong blowers or Good ventilation is manifest
airshields, may be when a continuous stream
clogged with dirt and of air leaves the motor. If
prevent proper not,check with manufactuer
ventilation of motor.

Motor may have Check to make sure that all


one phase open leads are well connected

Grounded coil. Locate and repair.

Unbalanced terminal Check for faulty leads,


voltage. connections and transformers.

Shorted stator coil. Repair and then check


watt-meter reading.

Faulty connections. Indicate by high resistance.

12
GO TO INDEX
1216 - 1217 VOL - C1 TAB - 3 - 30
SI.No. Trouble Cause Remedy

High voltage or Check terminals of motor


low voltage with voltmeter.
Rotor rubs stator If not poor machining,
bore replace worn bearings.
13. Motor vibrates: Motor misaligned. Realign.
after corrections
have been made. Weak foundations. Strengthen base.

Coupling out of Balance coupling.


balance.

Driven equipment Rebalance driven equipment.


unbalanced.

Defective ball or Replace bearings.


roller bearings.

Bearings not in line. Line up properly.

Balancing weights Rebalance rotor.


shifted.

Wound rotor coils Rebalance rotor.


replaced.
Polyphase motor Check for open circuit.
running single phase.
Excessive end play. Adjust bearing or add washer.
14. Unbalance line Unequal terminal volts. Check leads and connections.
current on
polyphase motors Single phase operation. Check for open contacts.
during normal Poor rotor contacts in Check control devices.
operation. control wound rotor
resistance.
Brushes not in proper See that brushes are
position in wound properly seated and shunts
rotor. in good conditions.
15. Scraping noise Fan rubbing air shield. Remove interference.
Fan striking insulation. Clean the fan.
Loose on bedplate. Tighten holding bolts.
16. Magnetic noise. Air gap not uniform. Check and correct bracket
fits bearing.

13
GO TO INDEX
1216 - 1217 VOL - C1 TAB - 3 - 31
SI.No. Trouble Cause Remedy

Loose bearings. Correct or renew.


Rotor unbalance. Rebalance.

NOTE : Certain amount of magnetic noise is inherent in some low speed designs and shouls not
cause alarm.

17. Motor sparking Motor may be Reduce the load.


at sliprings. overloaded.

Brushes may not be of Use brushes of the grade


correct quality and recommended.
may be sticking in the
holders.

Brush pressure may be Adjust the brush pressure


too light or too much. correctly.

Sliprings may be tough, Clean the sliprings and


dirty or oily. maintain them smooth
glossy and free from oil
and dirt.

Sliprings may be ridged Turn and grind the slipring


or out of truth. in a lathe to a smooth finish

5. MAINTENANCE SCHEDULE
The following Maintenance Schedule is suggested as a guide.

5.1 DAILY MAINTENANCE


a. Examine earth connections and motor leads.
b. Check motor windings for overheating. (Note that the permissible maximum temperature
is above that which can be comfortably felt by hand.)
c. Examine control equipment.
d. In the case of oil ring lubricated machines:
i. Examine bearings to see that oil rings are working.
ii. Note temperature of bearings;
iii. Add oil if necessary;
iv. Check and plays

14
GO TO INDEX
1216 - 1217 VOL - C1 TAB - 3 - 32
5.2 WEEKLY MAINTENANCE
a. Check belt tension. In cases where this is excessive it should immediately be reduced
and in the case of sleeve bearing machines the air gap between rotor and stator should
be checked.
b. Blow out windings of protected type motors, situated in dusty locations.
c. Examine starting equipment for burnt contacts where motor is started and stopped
frequently.
d. Examine oil in the case of oil ring lubricated bearings for contamination by dust, dirt,
etc. (This can be roughly ascertained on inspection by the colour of the oil).

5.3 MONTHLY MAINTENANCE


a. Overhaul Controllers.
b. Inspect and clean oil circuit breakers.
c. Renew oil in high speed bearings in damp and dusty locations.
d. Wipe brush holders and check bedding of brushes of slipring motors.
e. Check the condition of the grease.

5.4 HALF-YEARLY MAINTENANCE


a. Clean windings of motors subjected to corrosive or other element. Also bake and varnish
if necessary.
b. In the case of slip-ring motors check slip-rings for grooving on unusual wear.
c. Renew grease in ball and roller bearings.
d. Drain all oil bearings, wash with kerosene, flush with lubricating oil and refill with
clean oil.

5.5 ANNUAL MAINTENANCE


a. Check all high speed bearings and renew if necessary.
b. Blow out all windings of motors thoroughly with clean dry air. Make sure that the
pressure is not so high as to damage the insulation.
c. Clean and varnish dirty and oily windings.
d. Overhaul motors subject to severe operating conditions.
e. Renew switch and fuse contacts if badly pitted.
f. Renew oil in starters subjected to damp or corrosive elements.
g. Check insulation resistance to earth and between phases of motor windings, control
gear and wiring.
h. Check resistance of earth connections.
i. Check air gaps.

15
GO TO INDEX
1216 - 1217 VOL - C1 TAB - 3 - 33
5.6 RECORDS
Maintain a register (as per the specimen shown or enclosed) giving one or more pages for each
machine and record therein all important inspections and maintenance works carried out from
time to time. These records shall show past performance, normal insulation level, gap
measurements, nature of repairs and time between previous repairs and other important information
which would be of help for good performance and maintenance.

6. LIMITS OF TEMPERATURE RISE


Permissible maximum temperature rise for class ‘B’ insulation is
120°C
Ambient Temperature .... .... 65°C

16
GO TO INDEX
1216 - 1217 VOL - C1 TAB - 3 - 34
DATA SHEET FOR SOOT BLOWER MOTORS

SI. Description Long Retract Long Retract Wall Blower Wall Blower Rotary Blower
No.
01. Application Long Retract Long Retract Wall Blower Wall Blower Rotary Blower
Rotary Traverse Rotary Traverse Motor

02. Frame Size 80 80 71 90 71

03. Flange Type IS 2223 Type C IS 2223 Type C IS 2223 Type C IS 2223 Type C IS 2223 Type C

04. Dimensions( 4--20-201- 4--20-201-00303 4--20-201-00303 4--20-201-00303 4--20-201-00303


Drg.No) 00303

05. Power in KW 0.45 0.37 0.05 0.56 0.09

06. Rated 415 415 415 415 415


Voltage

07. No. of Phases 3∅ 50 HZ 3∅ 50 HZ 3∅ 50 HZ 3∅ 50 HZ 3∅ 50 HZ


& Frequency

08. RPM(Approx 1425 1365 1480 1425 1425


imate)

09. Duty 30 minutes 15 minutes Continous 30 minutes Continous

10. Ambient 65 65 65 65 65
Temperature
o
C

11. Enclosure & Totally Totally enclosed Totally enclosed Totally enclosed Totally enclosed
Protection enclosed non non ventilated IP non ventilated IP non ventilated IP non ventilated IP
ventilated IP 55 55 protection 55 protection 55 protection 55 protection
protection

12. Class of B B B B B
Institution

13. Voltage ± 10 ± 10 ± 10 ± 10 ± 10
Variation %

14. Frequency ±5 ±5 ±5 ±5 ±5
Variation

15. Combined ± 10 ± 10 ± 10 ± 10 ± 10
Voltage &
Frequency
Variation

16. Starting 1.1 0.46 0.245 1.09 0.29


Torque in
kgm.

17. Rated Torque 0.3775 0.264 0.0329 0.382 0.063

17
GO TO INDEX
1216 - 1217 VOL - C1 TAB - 3 - 35
DATA SHEET FOR SOOT BLOWER MOTORS(CONTD.)

SI.N o D escription Long Long W all W all Rotary


Retract Retract Blow er B low er Blow er

18. Breakdow n T orque 1.06 0.485 0.265 1.12 0.29


in kgm.

19. Full load current in 1.26 0.86 0.44 1.36 0.64


A mps.(A pproximat
e)

20. N o. of leads 6 6 6 6 6

21. N ame Plate Stainless Stainless Stainless Stainless Stainless


steel steel steel steel

22. Paint Epoxy Epoxy grey Epoxy grey Epoxy grey Epoxy grey
grey

23. Conduct size in the M 20 x M 20 x 1.5 M 20 x 1.5 M 20 x 1.5 M 20 x 1.5


T erm inal Box 1.5

24. Pow er Factor & 0.68 0.88 0.34 0.78 0.48


Rated
Load(A pproximate)

25. Efficiency in Rated 71% 75% 45% 73.5% 44%


Load
(A pproximate)

26. M axim um stalling H ot 20 H ot 40 sec H ot 35 sec H ot 30 sec H ot 35 sec


Time sec cold cold 75 cold 65 cold 55 cold 65
(A pproximate) 35

27. D irection of Reversibl Reversible Reversible Reversible Reversible


R otation e

28. O ther Construction Shaft end Shaft end Shaft end Shaft end Shaft end
al Features w ith oil w ith oil w ith oil w ith oil w ith oil seal
seal seal seal seal

29. W eight of M otor in 13.5 13.5 13.5 13.5 13.5


kg. (A pproximate)

30. G D 2 of M otor in 0.0073 0.0073 0.0027 0.0112 0.0027


kg.(A pproximate)

Go To Pub Index
18
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1216 - 1217 VOL - C1 TAB - 3 - 36
TAB - 4

GO TO INDEX
INSTRUCTION MANUAL
DESCRIPTION, OPERATION AND
MAINTANENCE

SOOT BLOWER
GENERAL INSTRUCTIONS

Bharat Heavy Electricals Limited


Tiruchirapalli

PUB.NO.7501

GO TO INDEX
1216 - 1217 VOL - C1 TAB - 4 - 37
CONTENTS
INTRODUCTION
IMPORTANT INSTRUCTIONS
GENERAL INSTRUCTIONS
PREVENTING PUFFS AND FURNACE EXPLOSIONS DURING SOOT
BLOWING
PROCEDURE FOR SETTING BLOWING PRESSURES FOR SOOT BLOWER
SYSTEMS
SOOT BLOWER CHECK LIST AND RECOMMENDED START-UP
PROCEDURE
SOOT BLOWER MAINTENANCE
RECOMMENDED LUBRICATION CHART FOR SOOT BLOWERS
RECOMMENDED QUANTITY OF LUBRICANTS FOR ONE YEAR
VALVE SEAT GRINDING FOR SOOT BLOWER VALVE HEADS
RECOMMENDED PROCEDURE FOR PACKING INSTALLATION
INSTRUCTIONS FOR STORAGE

2
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1216 - 1217 VOL - C1 TAB - 4 - 38
INTRODUCTION
This general instruction, sets some guidelines in preventing puffs and furnace explosions
during soot blowing and outlines the procedure for setting blowing pressures. A check list for
operation and a recommended procedure for start-up are given for general care and correct
start-up. The section on maintenance gives a detailed glimpse into the maintenance problem.
The lubrication schedule helps the maintenance man to choose the correct lubricant and carry
out the lubrication plans.
No Soot Blower system will operate satisfactorily if it is not properly installed, operated and
maintained. It must be recognised that no amount of written instructions can replace intelligent
thinking and reasoning on the part of the operators, especially when coping with unforeseen
operating conditions. It is the operators’ responsibility to become thoroughly familiar not
only with the equipment but also with all pertinent control equipment.
The instruction contained in this manual is only an outline of the correct procedures for
operation and maintenance. The contents in this manual have been compiled and checked by
experts in this field. Every possible care has been taken to ensure the contents are accurate.
Suggestions for the improvement of the manual are welcome.
If you ever have any query about operation, maintenance or related problems, you are welcome
to write to BHEL without obligation.
IMPORTANT INSTRUCTIONS
DO’S
1. CARELESSNESS IN REPAIRING SOOT BLOWING EQUIPMENT CAN CAUSE
SERIOUS INJURIES. ACCIDENTS CAN BE PREVENTED BY TAKING SIMPLE
PRECAUTIONS.
2. INCREASE FURNACE DRAFT BY APPROPRIATE ADJUSTMENTS OF THE
INDUCED DRAFT FAN TO TAKE CARE OF THE INCREASED FLUE GAS
VOLUME DUE TO THE SOOT BLOWING OPERATION. THIS WOULD HELP
TO PURGE COMBUSTIBLE GAS POCKETS.
3. AVOID SOOT BLOWING OPERATION WHEN THE REFRACTORY IS HOT
i.e.IMMEDIATELY AFTER STOPPING OR WHEN THE BOILER IS NOT IN
SERVICE FOR SOME TIME.
4. ALL STEAM LEAKS SHOULD BE ATTENDED TO IMMEDIATELY.
5. AVOID EXCESS BLOWING PRESSURE.
6. MAIN MEDIUM VALVE SHOULD BE CLOSED IMMEDIATELY AFTER THE
COMPLETION OF THE SOOT BLOWING OPERATION.
7. FOR LUBRICATION, FOLLOW THE LUBRICATION INSTRUCTIONS
CAREFULLY.
8. RETRACT THE LANCE IMMEDIATELY IN THE EVENT OF FAILURE OF
POWER TO AVOID DAMAGE TO THE LANCE.
9. EVEN IF THE BOILER IN OPERATION DOES NOT REQUIRE SOOT
BLOWING, KEEP THEM OPERATING AT LEAST ONCE IN A WEEK. THIS
WILL HELP IF COAL CHARACTERISTIC CHANGE AT A LATER DATE AND
TO KEEP THE SOOT BLOWERS IN ORDER.
10. ALL THE PEEP HOLES SHOULD BE CLOSED AND LOCKED BEFORE WALL
DESLAGERS ARE PUT INTO OPERATION.

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GO TO INDEX
1216 - 1217 VOL - C1 TAB - 4 - 39
11. DURING OUTAGES, CHECK THE CLEARANCE BETWEEN THE EDGE OF
THE LANCE TUBE AND THE SUPER HEATER, RE-HEATER TUBES. THERE
SHOULD BE A MIN. GAP OF 100MM.
12. THE SOOT BLOWER LINE MUST BE STEAM BLOWN BEFORE THE
BLOWERS ARE PUT INTO OPERATION AT THE TIME OF COMMISSIONING.
DON’TS
1. DO NOT ATTEMPT REPAIRS BEYOND YOUR ABILITIES.
2. DO NOT OPERATE THE BLOWERS WITH WET STEAM.
3. DO NOT EXTEND THE LANCE OF LONG RETRACT WITHOUT BLOWING
MEDIUM WHEN BOILER IS ‘ON’.
4. DO NOT OVERTIGHTEN THE PACKING.
5. DO NOT HAND CRANK THE BLOWERS WHILE THE POWER OR BLOWING
MEDIUM IS ‘ON’.
1. GENERAL INSTRUCTIONS
1.1 Ordering Repair Parts
When ordering repair parts, always give the Name, Part No., Drg. No., as found on the parts
lists and Model number as found on the brass name plate.
In the case of bearings and elements, swivel tubes or lances refer to Element Location Drawings
and give the Drawing No. for the specific piece needed. Elements may vary for different
locations.
If you have more than one boiler, give the type, size, rating and location of the boiler or
boilers for which parts are needed, and the order number under which you purchased the
Blowers for which parts are needed.
1.2 A Word of Caution
Carelessness in repairing a blowing equipment can cause serious injuries. Accidents can be
prevented by taking simple precautions.
Always get permission and clearance from the proper authority before starting to repair any
equipment.
Use proper lifting equipment for heavy equipment. Do not attempt repairs beyond your ability.
Before repairing any equipment operated by steam or air, make sure all supply valves have
been closed, tagged or locked and also the electrical connections are cut off. If steam or air
supply lines must be energised for purpose of test, use extreme caution.
2. PREVENTING PUFFS AND FURNACE EXPLOSIONS DURING SOOT
BLOWING
Explosions, puffs, or blow backs that occur during or as a result of soot blowing operations
should be reported to and discussed with the boiler manufacturer. It is impossible to establish
a definite procedure to prevent these difficulties because of the variation of fuels and the
design and operations of Steam Generating equipment. The start-up or operating engineers
working in conjunction with design engineers or boiler manufacturing firms are best qualified
to recommend procedures of operation on their particular equipment.
The following recommendations are presented for consideration when it is necessary to establish
operational procedure to prevent these difficulties.

4
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1216 - 1217 VOL - C1 TAB - 4 - 40
(i) Cleaning Cycle
As a guide line we suggest a soot blowing cycle of once in a day to start with may be established.
After watching the performance of the particular coal, oil or any other fuel, with reference to
the deposit formation, the blowing cycle can be altered. It is essential to have a satisfactory
cycle so that the heat recovery surfaces are kept free of deposits at the same time the tube
surfaces are not damaged because of frequent blowing. The life of the soot blower parts will
also proportionally decrease with increased frequency. The Boiler operating personnel can
establish the optimum blowing cycle depending on the actual furnace conditions. It is
impossible to predict the deposit formation since too many factors influence the same.
(ii) When possible, the boiler to be cleaned should be operating at or near the maximum
design load.
When soot blowers are operated at low boiler loads, clouds of soot may be blown into the gas
stream to form explosive mixtures which may be ignited by the heat from furnace walls or by
smoldering soot fires. Soot blower operation at low boiler load, with a resulting colder furnace
may also result in some of the unburned combustibles escaping from the furnace and collecting
in pockets in back passes.
Agitation and ignition of these gas pockets will cause puffs or explosions. All tube surfaces
and gas passes, therefore, should be blown with the gas flow at or near maximum to purge the
boiler of these possible explosion causes.
(iii) On oil or pulverised fuel fired boilers, soot blowers should be used with the burners
operating at the highest possible burning rate, maintaining even stable combustion.
Soot blowing schedules should be established to take place during the heaviest load
periods, or the burner firing rates should be increased during soot blowing. Burners
should be checked during soot blowing for stability.
A high burning rate assures a lower oxygen content in flue gases which eliminate the difficulty
as explained in (ii) above.
High and stable burning rates also prevent flames from being blown out by small puffs or
agitation of the gas flow common while soot blowing.
(iv) Before operating soot blowers the furnace drafts should be increased by opening the
boiler outlet damper or by making the appropriate adjustments of the induced draft
fan to take care of the increased flue gas volume due to the soot blowing operation.
Increased furnace draft helps to purge combustible gas pockets explained in (ii) above.
Increased furnace draft improves cleaning by moving soot particles through gas passes rather
than re-depositing them on adjacent surfaces.
(v) Conditions may require the operation of soot blowing equipment with the burners
out of service as when cleaning prior to outages to facilitate inspections.This procedure
is dangerous. If unavoidable, soot blowing operation should not proceed while the
refractory is still hot and there is any possibility of soot fires still smoldering in the
setting. Be sure the boiler is cold and inspect the setting for smoldering soot before
blowing.
(vi) The normal sequence of soot blowing is to follow the gas flow through the boiler.
The first soot blower to be operated should be the nearest to the burners then each
unit in turn along the gas passes to complete the cleaning cycle. This method
thoroughly cleans the entire unit by moving along the passes rather than blowing
them loose and redepositing them on adjacent surfaces. It may be desirable to reverse
this procedure when soot deposits are unusually heavy to avoid plugging and puffs
or explosions in the back passes.
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1216 - 1217 VOL - C1 TAB - 4 - 41
Blowers should then be operated in reverse order from rear to front to rear. This procedure
may be desirable during period of low load operation, as when units are banked, or on Marine
installations when ships are put out to sea after time spent in port.
(vii) For operating wall deslaggers,operate the row of wall deslaggers at the highest
elevation first and then follow downwards, so that, heavy slags dislodged and
deposited at lower elevation will be cleared by further soot blowing operation and
fall to the ash hopper due to its weight.
3. PROCEDURE FOR SETTING BLOWING PRESSURES FOR SOOT
BLOWER SYSTEMS
3.1 Introduction
All large, high pressure boilers and many medium and small boilers today employ a pressure
reducing valve in the steam supply to the soot blower system. This requirement, coupled with
the fact that all individual soot blower operating head pressures can be easily adjusted externally
while the units operating, permits adjustment of the blowing pressures without internal orifices
and at the same time permits operation of the system on a relatively low supply pressure.
The reduced supply pressure reduces packing and valve maintenance and makes the system
more flexible for pressure adjustment at later dates without the necessity of installing orifices.
A step by step procedure is outlined to attain this set up.
Use the pressure gauge and the connected fittings issued by us for measuring the blowing
pressure. Connect the pressure gauge fittings as shown in the figure.
3.2 Recommended Blowing Pressures
The suggested blowing pressures are listed out in the blowing pressure table, released in
00,076 erection drawing group separately for each contract.
When these pressures are not shown on the blowing pressure Table BHEL should be contacted
for this information. Request for this information should be complete with blower no. location
and the existing blowing pressure.
3.3 Customer Information
It is a most important step that the customer, the operators and the maintenance personnel
understand that these Recommended Blowing Pressures are based on past experience with
similar fuels, boiler design and firing conditions. The pressures are recommended for trial as
a starting point. Blowing pressures are those that are required to clean can only be determined
after a period of operation and trial settings with adjustment later, if necessary.
3.4 Set High Pressure First
The unit marked for highest blowing pressure on the Blowing pressure table is set up first.
This will usually be a retractable unit in the platen section or in front of the slag screen,
(i) The valve head is designed for high pressure. The valve opening of each blower is
adjusted using the setscrew to the required blowing pressure such that the valve dis
is opened fully or partially without completely compressing the spring (i.e. spring
should not be solid).
(ii) The steam supply is then turned on and the pressure recommended is set on this high
pressure unit from the blowing pressure table by adjusting the supply pressure at the
Pressure Reducing Valve. As an example the blowing pressure on this first unit may
be 18 Kg./cm2 and the supply pressure may be as low as 21 or 25 kg/cm2 depending
on line drop.

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1216 - 1217 VOL - C1 TAB - 4 - 42
3.5 Set Pressures on Other Models
The next step is to set pressures on one each of the other models in the system – one wall
deslagger, one rotary and one air preheater cleaner if they are employed in the particular
system.
In selecting the one unit of each of these models to be checked, consideration should be given
to the highest blowing pressure used on that particular model as well as the unit farthest from
the source of steam supply. Line drop will be the only reason for not being able to obtain the
recommended pressures.
Where pressure cannot be set as high as desired because of line drop on these secondary
model settings, it obviously will be necessary to increase the supply pressure through the
Pressure Reducing Valve and reduce the pressure on the individual high pressure unit first set
up.
3.6 Setting Pressure on all Other Units
From the above procedure we have established the minimum header supply pressure to give
the maximum blowing pressure on all of the various soot blower models or types of equipment
used in the system. It is now only necessary to set the other pressure by restricting valve
opening on other units using lesser pressures.
These pressure settings must be made with pressure gauges and the units in actual operation.
Measuring the valve opening or using feeler gauges is not reliable since accumulation of
tolerances in the valve linkage causes a variation in pressure settings.
Normally, no alteration is necessary to the safety valve setting. The seal on safety valves must
not be broken or changes made to these safety settings without specific reasons. Safety valves
are for the protection of the equipment and system in case of Pressure Reducing Valve failure
and their setting does not coincide with this method of pressure setting in any way.
PRESSURE SETTING ARRANGEMENT

ITEM NO. OFF BPS W. DRG. NO DESCRIPTION


NO.
01 1 3.20.998.00796 CONDENSING LOOP
02 2 4.20.998.0 1763 PACKING (COPPER)
03 1 4.20.998.01759 CONNECTOR
04 1 V75 141 0250 PR. GAUGE 150 RANGE 0.70 ata

Safety Valve set pressure


Because of the pressure fluctuations occuring in the system when each soot blower valve
head is opened and closed the slow reaction of the Pressure Reducing Valve actuator the
safety vave is likely to pop or chatter depending on the set pressure. The set pressure can be
7
GO TO INDEX
1216 - 1217 VOL - C1 TAB - 4 - 43
increased if the set pressure is not already in the maximum setting. Normally a set pressure
upto 42 Kg./cm2 (g) can be set with a 600 psi rated safety valve.
Do not alter the set pressure if the system is stable.
With the above procedure of setting pressure we have the maximum valve opening possible
on any and all individual soot blower operating heads which reduces valve maintenance. We
have the minimum steam pressure on packing, also reducing maintenance.
We have a more flexible system in that, if loads are increased or inferior fuels are used for
shorter periods where higher blowing pressures are required, one single adjustment can be
made at the pressure reducing valve rather than changing and gauging all individual units.
When the emergency is past, the original pressures can be restored again with one adjustment
at the pressure reducing valve.
If there are questions or if difficulties should arise in following this procedure, please contact
us for further advice and counsel.
Do not set pressure reducing valve supplied systems at 600 psi and reduce blowing pressures
with orifices and individual head linkage adjustment.
3.7 Blowing Pressures
When new jobs are commissioned or started up, we can , based on past experience with the
type of fuels, firing, boilers and equipment involved, recommend blowing pressures for trial
or starting. An operating period then dictates if pressures and operating frequency should be
changed.

Pressure Adjustment In Long Retract

Observation while the boiler is in operation and inspections at outages are always necessary
to see that cleaning is adequate and that tube damage does not result. In order to evaluate
either cleaning problems or tube erosion and determine corrective steps to be taken, down
steam blowing pressures should be gauged and tabulated along with the operating frequency
of the units.
Pressure, nozzle size, nozzle angle, drainage of condensate and frequency of operation items
that should be reviewed and checked relative to cleaning and erosion conditions. We wish the
customer to feel free to call on our service department for advice and counsel which will be
based on our past experience in this type of work.
3.8 Inspections
Inspections of all tube surfaces at any scheduled outage, are essential to determine tube damage
and cleaning. Wall blower inspection is difficult and costly because of the need of scaffolds
or bosunchair, nonetheless inspection is necessary because of the fact that they are hard to see
and check while in operation.
8
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1216 - 1217 VOL - C1 TAB - 4 - 44
We recommend that inspection be made at every scheduled outage of sufficient length to
permit installing a bosunchair or scaffold. We also recommend that inspection be made of all
the tube surfaces at each blower location as soon as the boiler is cool enough to enter and
before any hand cleaning is accomplished. This early inspection gives true picture of the
deposits before they are disturbed and also permits repair during the scheduled outage.
4. SOOT BLOWER CHECK LIST AND RECOMMENDED START-UP
PROCEDURE
4.1 Blowing Medium Supply System
(i) Steam System
(a) Check expansion loops for thermal expansion provision.
(b) Check for slope or pitch for drainage as called for on drawings.
(c) Condensate discharge from trap should be led to atmospheric pressure.
(d) Condensate drain should slope down and away from trap for gravity drain.
(ii) Both Air and Steam Systems
(a) Check provisions for boiler expansion
Expansion loops provided on steam system
Flexible couplings or expansion loops on air system.
(b) Pipe Hangers
Sufficient in number
Properly located to eliminate any pipe strain on soot blower inlet
flange when system is in hot operating position.
(c) Blow down either system completely
On “Candelabrum” or gradually rising header and branch line systems,
it is recommended that all branch lines be blown before inlet
flanges of soot blower operating heads are made up.
On properly designed drain systems having a drain connected to each
operating head, blowing down of construction debris and cleaning
lines can be limited to blow down of drain lines and condensate
reservoir immediately preceding the drain valve.
(d) Drains
All drain lines must be blown down before final welding in of the
drain valve proper.
The thermometer or thermocouple should be checked for goodworking
conditions.
4.2 Suggested Operation Procedure
(i) The frequency of soot blower operation depends on the operting conditions, status
of the boiler and boiler cleanliness. Some things which may indicate the need for
cleaning are; increase in boiler exit gas termperature, decrease in boiler gas flow
(assuming constant boiler load) and visual inspection.
(ii) It is important when starting up a boiler that the soot blowers be used frequently and
soon after lighting off. Inefficient combustion in a boiler being started up may result

9
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1216 - 1217 VOL - C1 TAB - 4 - 45
in abnormal deposits on the tubes. Unless they are removed frequently, furnace
explosions or puffs may result later. It is usually also desirable to use the soot
blowers just before taking a boiler out of service.
(iii) When using the soot blowers for the first time, it is advisable to increase the furnace
draft as much as possible during the blowing cycle. After several blowing cycles, it
will be possible to tell how much the furnace draft shoud be increased for blowing.
The furnace draft can be increased by opening the boiler outlet damper wider, in
creasing the induced draft fan speed, or opening the induced draft fan damper wider.
No increase in forced draft is recommended.
(iv) When the soot blowers are not being used, the main steam supply valve should
always be closed tightly and the drain valves opened wide. The motor equipment
for electrically driven blowers is housed in suitable enclosures. For all blowers it is
necessary to make the power and control connections from the motor control centres
and panel to each blower. There is usually a local starting button for each blower as
well as a remote button on the control panel. These buttons are indicated on the
wiring diagrams.
(v) Suggested Procedures
(a) Assure that power is available at the proper voltage and frequency as specified on
the application drawings.
(b) Increase the furnace draft as described above.
(c) For steam blowing systems, open all drain valves wide. If traps are used, be sure
isolation valves are open and the by-ass valve is closed.
(d) Open the main steam or air supply valve slowly until it is wide open. With steam
blowing cycle, do not operate any blowers until all the piping has been warmed and
drained. Then, if traps are not used, close the drain valve. The hole in the valve seat
will serve to keep the lines drained. Never blow with wet steam.
(e) Operate the blowers in the numerical sequence shown on the general arrangement
drawing. There is a panel “start” push button for each blower. The buttons may be
included in the automatic sequential operation; they may be individual (buttons for
manual operation) therefore, one button must be used to start each blower. Each
button should be held in about 5 seconds and then released. The blower will start
operating, complete the cycle and this will be indicated in the panel; start the next
blower after this blower operation is over.

Pressure Adjustment wall Deslagger

10
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1216 - 1217 VOL - C1 TAB - 4 - 46
(f) Operate each blower in sequence, each may be operated as many times as necessary
to clean. (Note: Allow a cooling period of 1 hr. before subsequent operaion of the
same blower) NEVER ALLOW A BLOWER TO BLOW UNLESS THE NOZZLE
IS ROTATING.
(g) When the entire blowing cycle is complete, close the main stop valve tightly. Open
the drain valves wide if they are closed.
(h) Adjust the furnace draft to Normal.
(i) Open the power and control circuit.
(j) Be sure all blowers have completely retracted and all heads are fully closed.
5. SOOT BLOWER MAINTENANCE
5.1. Soot blowing, once considered a necessary evil, has become a positive necessity on
modern coal and oil-fired boilers. Fuel costs are rising, and heat value per pound of
fuel seems to be decreasing. Ash, sulphur and low-fusion-temperature slags cause
more trouble with lower Bth. U fuels and demand dependable soot blower operation.
Many cost-conscious engineers are now setting up suitable maintenance programme on soot
blowers, and since peculiarities of each boiler plant usually require a programme tailor-made
for each plant, it is advisable to enlist the aid of the manufacturer’s field-service engineers in
setting up a specific programme. However, the following paragraphs will help to bring light
the more important things to be considered.
The factors that may cause, or contribute to tube cutting are:
(i) Excessive pressure causing excessive nozzle or jet velocity.
(ii) Abrasive dust from baffles and sheaves adjacent to blowers entrained in the blowing
jet.
(iii) Condensate in steam, or water in air, whichever is used as the blowing medium.
(iv) In air heaters or economizers where dew points may be low or boiler gases highly
corrosive tube metal may be rusted or eaten away, especially where any condensate
or drops of water from blower elements may be deposited on tube surfaces. These
rust scales are removed when blowers are operated, thus exposing new metal and the
cycle continues until tube failure occurs.
To check tube erosion
(a) Observe, report and record any tube erosion, cutting or polishing that is evident in
the slightest degree. The permanent record will help determine on future inspections
whether the condition has been corrected.
(b) Blowing pressures may be reduced on some equipment by adjusting the valve screw,
on other equipment by adjustable orifices in still other equipment by a permanent
orifice in the line. Manufacturer’s service instructions will indicate the proper
procedure. No higher pressure should be used than that needed to clean the boiler.
This decreases tube erosion and prevents excessive use of steam or air, thus aiding
economy.
(c) Follow the instructions given under individual blowers.
5.2 External Inspection
(i) Make sure valve mountings or head supports are secure. Loose mounting permits
head and element to move in and out of the wall sleeve, undoing all the careful
internal alignment.
11
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1216 - 1217 VOL - C1 TAB - 4 - 47
(ii) Check the operating head and valve to make sure it is functioning properly,
mechanically and that it can rotate without undue binding.
(iii) See that mechanical parts are clean and free from rust. Dirt and rust act as an
abrasive, causing moving parts to wear.
(iv) Remove immediately any and all water pockets in the supply piping system. PROPER
DRAINING OF PIPING IS OF PRIME IMPORTANCE. When the blowing medium
is steam the supply pipe should have an independent direct connection to the boiler
drum, to obtain the direct possible steam at maximum pressure. Stem supply piping
should be insulated for safety, and to reduce condensate in the soot blowing system.
(v) Make sure piping connections to soot blowers are flexible enough that no leakage
to abnormal stresses will develop. Proper hangers should be provided for the pipe.
Pipe risers should never depend on the soot blower head for any support. This always
causes binding when the unit is operated.
(vi) If condensate traps are used on steam systems, dis-assemble them and clean the
screens during outages to make sure they operate properly.If a drain valve with
4mm hole in the seat be used instead of a trap, make sure it is in place and in
operating condition.
(vii) Make sure condensate is drained to atmosphere. If drains are led to blow-down
tanks, check valves should be used. If drain systems are connected in series to two
or more boilers, check valves should be used to prevent steam from backing up on
unused equipment.
5.3 Maintenance
Things listed so far have been inspection points to check during boiler outages. There are
other points that can be checked while the boiler is in service.
(i) Operation personnel should be instructed to report immediately to the maintenance
personnel any difficulty encountered in operating.
(ii) Competent maintenance personnel should be required to follow and observe each
and every soot blower through its operating cycle on certain definite dates. These
inspection periods should be bi-weekly or monthly, depending on the size and
importance of the soot blower installation to proper boiler operation.
(iii) All steam leaks should be corrected immediately.
(iv) All valves should seat tightly to prevent wire drawing.
(v) All packing glands should be drawn just tight enough to prevent leakage without
binding or breaking down packing fibre by excessive pressure.
(vi) All cams and moving parts should be cleaned and properly lubricated.
(vii) Gear boxes should be filled to proper levels with correct gear oils or grease. Greases
should be checked regularly to see if they have hardened or separated from their
bases because of high ambient temperatures. On outdoor installations, they should
be checked when temperatures drop to see if hardening or channelling occurs.
(viii) Lubrications in air lines to air motors should be checked at least once a week to
make sure oil reservoirs are full and feed is correct.
(ix) With electric motors, insulation, brushes and commutators should be clean and free
from oils. General rules for care of electrical equipment and industrial controls
should be followed.

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1216 - 1217 VOL - C1 TAB - 4 - 48
(x) Where drive chains are used, the chain should be kept as dry as possible.Only enough
oil to prevent rust should be applied. Excess oil picks up fly ash and grit to form a
cutting abrasive between link connections.
(xi) With any lubricants, manufacturer’s specifications for correct types, amounts and
frequency of application should be closely followed.
5.4 Preparing for outages
Where boilers are subject to extended outages, as in heating plants, maintenance can be reduced
by giving proper attention to the equipment before and during the down period.
(i) Moving cams, etc., should be well coated with rust-preventive lubricants.
(ii) Mechanical units should be covered with canvas, oil cloth or paper for protection
against moisture or excessive dust.
(iii) If operating valves or pistons have rings or parts not made of rust-resistant alloys
these parts should be removed. They can be protected by a rust inhibitor by a rust
inhibitor or stored until the equipment is required.
(iv) Where feed lines or telescope tubes are of carbon steel, the units should be extended
and rust preventive applied to these parts.
(v) Inspections and repairs should be made immediately when the boiler is shut down to
assure proper operation when the boiler is put back into service.
Care, adjustment and maintenance of automatic control, panels for automatic-sequentital
systems are properly entrusted to the instrument personnel. Such systems usually require
little care after being placed in service, except to keep all parts thoroughly clean.
Generally speaking, they require the same maintenance as any industrial control system except
that the loads on relays, indicator lamps and switches are comparatively light, therefore,
requiring less attention. Little maintenance trouble is met, if this equipment is kept clean and
free from dust and oil.
5.5 Operation
Correct operating procedure will help to minimize maintenance problems. These are important
check points.
(i) Drain valve should be fully open, and supply valve opened slowly, during warm-up
period. Drain valve should not be closed until the steam leaving the drain is absolutely
dry. Drain valves should remain open when units are not operated. These precautions
prevent condensate from entering elements to warp or distort them.
(ii) Rotation of elements should be slow, even and continuous from the time steam flow
starts until it is shut off. Should the automatic valve-in-head unit fail to shut off, the
entire system should be shut down immediately, and the offending unit be corrected
or blanked off before proceeding with the other units in the cleaning cycle. To proceed
with the other units after one operating head has failed to shut off would cause tube
damage. In addition, there would be reduced blowing pressures to the other elements
which would prevent proper boiler cleaning.
(iii) All units should be kept in operating condition as far as possible. Loss of one unit
could cause plugging and thus divert hot gases over an adjacent unit to destroy that
element.
(iv) Blowers should be operated in proper sequence along the gas flow lanes with dampers
fully open. This moves soot out, rather than blowing it from one place to another.

13
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1216 - 1217 VOL - C1 TAB - 4 - 49
Boiler load should be ¾ to full, if possible to prevent puffs or possible explosions.
(v) Blowers should be operated at proper intervals to reduce temperatures and prevent
loss of elements and nozzles. Operating intervals should not be set for certain hours
of the day or shift, unless the boiler steams vary evenly and neither soot nor slag
conditions are of much concern. Blowing intervals should be adjusted to load, firing
and fuel conditions. The guiding rule is that flue gas temperature should not rise
more then 20 Deg. C between soot blower operating periods.
Soot blowers should also be operated after any abnormal fuel burner operation resulting in
heavy smoke while burning oil. This is especially true if there is an economiser or air heater.
Soot blowers are expected to clean efficiently and safely. They are intended to operate on low
power and labour cost, and to give long life with minimum maintenance expense. This is
possible, even if the equipment be subjected to high temperatures and adverse operating
conditions.
Soot blowing engineering takes these points into consideration and uses the highest possible
engineering standard in design and construction. As a result, blower equipment properly
installed and cared for is as trouble-free as possible. To maintain this standard of operation
requires only a regular programme of inspection and preventive maintenance.

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1216 - 1217 VOL - C1 TAB - 4 - 50
6.RECOMMENDED LUBRICATION CHART FOR SOOT BLOWERS
6.1 LRD-IE Long Retractable Soot Blower and LRD-IA Long Retractable Soot Blower (Air -Operated)

LUBRICATION FILLING QTY PER


PART OBSERVATION M ETHOD OF
POINTS LUBRICANT FREQUENCY BLOWER PER REMARKS
DESCRIPTION FREQUENCY APPLICATION
FILING

Power Pack Servosystem Fill the reservoir


1.1 Annual 3 Months 0.8 litre See Note 2
(Rotary) 68 removing vent plug
Power Pack Servosystem Fill the reservoir
1.2 Annual 3 Months 0.8 litre Sea Note 2
(Traverse) 68 removing vent plug
Servosystem See Note 1
1.3 Chain - - - -
150
Travelling Almasol
carriage 1250 or See Note 3
1.4 Annual 3 Months Fill in the reservoir 0.6 Kg
(Steam Servogem
Blowing) HTXX
Travelling
Servomesh
1,5 carriage Annual 3 Months Fill in the reservoir 0.6 Kg -
28
(Air Blowing)
Only for
1.6 Air Motor Servospin 6 2 Months 2 Months Air line lubrication I litre
LRD- IA
15

NOTE: 1 All the chain and chain links are prelubricated by special treatment by which lubrication is required normally. But as and when sign
of rust is identified twofold lubrication is recommended. First the chain is cleaned and trichloroethylene is applied over surfaces.
(This is used as a degreasing agent and carrier for penetrating the heavy lubricant. Servosystem 150 is applied as a second cost).
NOTE: 2 Lubricating oil levels should be checked and maintained every month.
NOTE: 3 Almasol 1250 is recommended only when the soot blowing medium temperature exceeds 427’C. For recovery boiler irrespective of
temperature Almasol 1250 is recommended.
1216 - 1217 VOL - C1 TAB - 4 - 51

GO TO INDEX
6.2 RECOMMENDED LUBRICATION CHART FOR LRD-IIE LONG RETRACTABLE SOOT BLOWER

LUBRICATION FILLING QTY PER


OBSERVATION M ETHOD OF
POINTS PART DESCRIPTION LUBRICANT FREQUENCY BLOWER PER REMARKS
FREQUENCY APPLICATION
FILING

Travelling carriage Servomesh Fill in the See Note 2 in


2.1 Annual 3 Months 0.8 litre
(Air Blowing) 28 reservoir section 6.1

Travelling carriage Almasol Fill in the See Note 3 in


2.2 Annual 3 Months 0.6 Kg.
(Steam Blowing) 1250 or reservoir Section 6.1

Servosystem See Note 1 in


2.3 Chain - - - 1
16

150 Section 6.1

Power Pack Rotary Servomesh Fill in the See Note 2 in


2.4 Annual 3 Months 0.8 litre
and Traverse 28 reservoir Section 6.1
1216 - 1217 VOL - C1 TAB - 4 - 52

GO TO INDEX
6.3 RECOMMENDED LUBRICATION CHART
FOR
RB-IM ROTARY SOOT BLOWERS -MANUAL
RB-IE ROTARY SOOT 6 LOWER S-ELECTRICALLY OPERATED
RB-IA ROTARY SOOT BLOWERS-AIR-OPERATED

LUBRICATION FILLING QTY PER


OBSERVATION M ETHOD OF
POINTS PART D ESCRIPTION LUBRICANT FREQUENCY BLOWER PER REMARKS
FREQUENCY APPLICATION
FILING

Fill in the See Note 2 in


3.1 Power Pack Servosystem 68 Annual 3 Months 0.5 litre
reservoir Section 6.1

Bull gear/(cluster Servogem 3 or


17

32 gear of Manuel rotary) Servogem 2 Months 1 Month Apply grease 0. 5 kg -


HTXXX

Air line O nly for RB-


3.3 Air motor Servospin 6 2 Months 2 Months 1 litre
lubrication lA
1216 - 1217 VOL - C1 TAB - 4 - 53

GO TO INDEX
6.4 RECOMMENDED LUBRICATION CHART OF WB-IE WALL DESLAGGER

LUBRICATION FILLING QTY PER


PART OBSERVATION M ETHOD OF
POINTS LUBRICANT FREQUENCY BLOWER PER R EMARKS
D ESCRIPTION FREQUENCY APPLICATION
FILING

Gear Rack Servomesh Fill in the See N ote 2 in


4.1 Annual 3 Months 0.5 litre
Housing S P 460 reservoir Section 6.1

Servogem 3
Pressure
4.2 Linkage or Servogem 2 Months 2 Months 0 . 1 kg
filling
HTXXX

Rotary gear box See N ote 2 in


18

Servomesh Fill in the


4.3 (steam blowing) Annual 3 Months 0,5 litre Section 6.1
S P 460 reservoir

Fill in the For Air


4.4 Rotary gear box Servorex LO Annual 3 Months 0.5 litre
reservoir operation only
1216 - 1217 VOL - C1 TAB - 4 - 54

GO TO INDEX
6.5 RECOMMENDED LUBRICATION CHART-FTP-IE FURNACE PROBE AND THE TRAVERSING SOOT
BLOWER

LUBRICATION FILLING QTY PER


PART OBSERVATION M ETHOD OF
POINTS LUBRICANT FREQUENCY BLOWER PER REMARKS
DESCRIPTION FREQUENCY APPLICATION
FILING

See Note 2 in
Fill in the
5.1 Power pack Servosystem 68 Annual 3 Months 0.8 litre Section 6.1
reservoir

See Note 1 in
5.2 Chain Servosystem 150 - - - - Section 6.1
19
1216 - 1217 VOL - C1 TAB - 4 - 55

GO TO INDEX
6.6 Comparable Equivalents of international Lubricants

Sl. Indian Oil Hindus tan Te xaco and *Lubrication Bharat


ESSO She ll Gulf M obil Exxon
N o. Corporation Pe trole um Calte x Engine e rs Inc. Pe trole um
Mobil Delvac Bharat
Servosystem Terresso 52 Shell Tellus oil 33 Regal oil PC Extra Motor oil
1. Enklo 68 Harmony 61 - special 1O W- Hydrol 68
68 or Nuto 53 (R&O ) 1O W- 30
30
Servogem Mobil Bharat MP
Davina Grease Thermatex
2. HTXXX or - - Gulf Leymoly - temperature - Grease 3
N o. 2 EP- 1
Servogem 3 grease 78
Mobil
Pen- o- led Meropa oil EP Lubricant 65 Compound BB Exxon spartan
3. Servomesh 28 Gervil EP15 Macoma oil 68 - -
EP2 N o. 2 (Mobil Gear EP 150
62.9)
Mobil
Meropa Bharat
Sarvomesh Pen- o- led EP Lubricant compound FF Exxon spartan
4. Gervil EP460 Macoma oil 78 lubricant No. - Amocam oil
S P 460 EP5 115 (Mobil gear EP 460
5 460
634)
20

Shell Alvania Texaco Gulf crown Exxon Lidok


5. Servorex LO Limaplexo Nebula EPO - Mobilux EPO
Grease EPO Multifak EPO Grease EPO EPO -
Velocite E Bharat
Exxon Avox EP
6. Servospin 6 Spintek 12 Spinnesso 34 Shell Tellus oil 10 Spintex RS Gulf spin 35 - (gargoyle Arctic Hydrol 15
45
oil light)
-
7 - - - - - - Almasol 1250 - -

Bharat
Servosystem Vactia oil extra
8 Yantrol 150 Vitrea 69 Texol ' F ' Gulf EB 7 - Hydrol 150
1216 - 1217 VOL - C1 TAB - 4 - 56

150 heavy

Note 1: Address of this firm is M/s.Lubrication Engineers Inc., Post Box No. 7128,Forth Worth, Texas 7611, USA.
Note 2 : The equivalent lubricants listed above will not have the same characteristics,but they can be used considering the application. names of
equivalent lubricant are based on the information available with us.Any revisions in the name of equivalent lubricant may be confirmed
with the respective lubricant manufactures.

GO TO INDEX
7.RECOMMENDED QUANTITY OF LUBRICANTS FOR ONE YEAR

Lubricant 40 AN D
Sl. N o. TYPE OF BLOWER UN IT 1-6 7-12 13-18 19-24 25-30 313-40
ABOVE
Almosal 1250
Long Retractable Model LRD- I E
1. Almosal 1250 STEAM BLOWING K g. 6 12 18 24 31 40 -
Long Retractable Model LRD - II E

-
2. Servomesh 28 Long Retractable Model LRD- 1 E (Air Slowing) Lit. 9 18 27 36 45 54

Long Retractable Model LRD- 11 E (Air -


Servomesh 28 Lit. 9 18 27 36 45 54
Blowing)
Long Retractable Model LRD- 11 E (Steam -
Servomesh 28 Lit. 9 18 27 36 45 54
Blowing)
-
3 Servosystern 68 Long Retractable Model LRD- 1 E/I A Lit. 12 24 36 48 60 80
21

-
Rotary Blower RB- 1 E Lit. 4 8 10 12 18 24

60
4. Servomesh 60 Wall Blower WB- l E (Steam Blowing) Lit. 5 12 18 24 30 40

30
Wall Slower WB- l E (Air Blowing) Lit. 3 5 9 12 15 20

-
5. Servogem HTXXX Long Retractable LRD- 1 E K g. 12 24 36 48 60 80
1216 - 1217 VOL - C1 TAB - 4 - 57

-
Long Retractable LRD- 11 E K g. 18 36 54 72 90 120

30
6. Servorex LO Wall Deslagger (Air driven) Lit. 3 6 9 12 15 20

60
7. Servospin 6 All types of air operated Blowers Lit. 5 10 15 20 25 30

40
8. Trichloroethylene Long Retractable Model LRD (All Types) Lit. 3 6 9 12 15 30

40
9. Servosysterm
n 150 Long GO
RetracTO
table Model LRD (All Types)
INDEX Lit. 3 6 9 12 15 30
8. VALVE SEAT GRINDING FOR SOOT BLOWER VALVE HEADS
8.1. Caution
DO NOT re-grind seats unless absolutely necessary. Every attempt should be made to lap
seat and valve into condition without using the re-grinding tool.
Only when the normal valve grinding procedure with valve grinding compounds does not
remove cuts and wire drawing from the seating surfaces should be grinding tool be resorted
to.
DO grind very lightly.
When the grinding tool is employed only sufficient grinding should be done to remove
imperfections. Removing hard stellite face unnecessarily is wasteful and time consuming.
DO maintain a 210 angle on the fixed seat in the main body and 19-1/20 angle on valve disc
of the valve assembly.
It is permissible to be off a few minutes from these angles on both seating surfaces.
We endeavour to maintain full width contact for greater life expectancy. This is desirable
rather than the “ring” contact which would be present with different angles on the matching
seats. The “ring” contact seal cuts through and starts to leak in a relatively short time.
8.2 Disassembly of Operating Heads
All valve heads are stripped down whether removed or still in place on the unit. The valve
disc and all packings are removed. The packing gland remains in place.
Where packing glands show wear at the valve stem guide area or are to be replaced for any
reason, the replacement should be made before re-seating is done.
The packing gland is used as a guide for the pilot and the stone sleeve in the re-seating procedure.
The packing gland must therefore remain in place after grinding to insure concentricity of the
operating parts when the unit is re-assembled.
8.3 Test Checking Valve and Seat
Immediately after dis-assembly an examination of the parts should be made to see that they
are not fractured or broken beyond repair that would require replacement. The seating surfaces
are then checked.
Cracked seat surface in the valve body may require re-stelliting. This is not a recommended
field procedure. The valve body with packing gland and valve stem assembly should be returned
to our plant for re-stelliting and grinding in the valve.
The valve stem assembly may be craked or the valve stem worn or scored requiring replacement.
The packing gland may be worn in the valve stem guide area and require replacing.
When the body with the final packing gland in place is available the valve assembly is then
lapped with fine valve grinding compound. The valve grinding compound should be the
water mixed automotive type. The procedure for lapping the valve is comparable to automotive
valve grinding using the screwdriver slot in the top of the valve disc to rotate the valve with
compound on the seat surface.
This light test lapping will indicate the extent of wire drawing, cuts or imperfections in the
seating surfaces. From this test lapping, it can be determined if heavy grinding compounds
and continued hand grinding with fine lapping compounds used in turn will correct the surfaces
or if it will be necessary to resort to the more drastic valve re-grinding.

22
GO TO INDEX
1216 - 1217 VOL - C1 TAB - 4 - 58
8.4 Dressing the Grinding Stone
The stone is installed on the stone sleeve by turning the threaded end of the sleeve into the
threaded bushing in the stone.
The stone on the sleeve is then installed on the lightly oiled upright stem of the grinder.
The sleeve and stone assembly is then rotated with the driver.

Valve Seat Grinding Tool set


1.Drive RPM of Drive Shaft = 12000 4. Stone Sleeve
2.valve Body 5. Stone (Norton ME 105420 or Equivalent)
3.Pilot
The cutting angle of the diamond point “dresser” should be set on the angle indicator to 210.
The dressing of the stone should be with very slow feeds of the micrometer adjustment in the
diamond feed screw to avoid waste and damage to the stone.
8.5 The Pilot
The pilot is then installed in the soot blower head from the stuffing box side. Pilot “plug”
should enter and fit snugly in the packing box of the packing gland in order to insure
concentricity of the newly made seat with the guide of the packing gland.
8.6 The Stone Sleeve and Stone Assembly
The sleeve and stone assembly is then inserted in the operating head from the opposite side of
the packing gland. The stem on the pilot entering into the sleeve should be lightly oiled. A
minimum amount of oil should be used to avoid oil loading of the grinding stone.
8.7 The Driver
The driving head is then fitted into the sleeve. The stone should be off the seat and ride on the
pilot stem only as driver is started. The driver with sleeve and stone assembly is advanced
slowly until the seat surface is contacted only very lightly. The driver is then withdrawn very
slowly. Cutting on these seats is extremely rapid because of the angle, therefore, we repeat,
proceed slowly in removing metal. A slight check after the first touch will indicate if additional
grinding is required.
8.8 Valve Stem Assembly
The valve disc of the valve stem assembly may be cut or wire drawn with marks too deep to
remove by compounds and hand work. These assemblies can be dressed to the 20 Deg. with
a grinder in a lathe or a regular automotive valve grinder.
Extreme care should be exercised where the disc seating surface of the valve stem assembly is
ground or refinished that excessive metal is not removed.

23
GO TO INDEX
1216 - 1217 VOL - C1 TAB - 4 - 59
Never more than a total of 0.25mm should be removed from the face of the disc on the valve
stem assembly as it is received from the factory. Removing excessive metal by this grinding
of the disc on the valve stem assembly will reduce the diameter and thin the seating wall of
the valve disc permitting it to be driven through the fixed seat. This is not dangerous to
personnel but does impose a more expensive maintenance problem. We recommend
replacement of the valve stem assembly when the seat surface is damaged.
8.9 Check for Mating Seat Angle
When both seating surfaces have been regrouped the mating angles can be checked by the use
of Prussian Blue. With blue applied to the seating surface a light turn of the valve assembly
will indicate not only imperfections but will determine if the angles of both seat and valve are
identical in the lapped area. The fixed seat in the body should show full width contact on the
valve disc rather than “ring” contact. If “ring” contact is apparent the angle on the grinding
stone may require a slight correction in the “dressing” angle.
8.10 Re-dressing the Grinding Stone
The grinding stone should not be permitted to develop a ring or groove between ‘dressing.
The side angle of the stone should remain straight and flat. “Dressing” is also essential to
prevent oil carbon loading.
8.11 Lapping after Grinding
When seats have been reground the valve should be hand lapped with very fine lapping
compound. This procedure again is very very light. Only sufficient pressure is applied with
a very few turns so that a fine “frosted” surface appears on the newly polished ground parts.
Actually this lapping procedure should be more of a check to see that surfaces properly made
on both parts. Figures show a hand tool suggested for this purpose.
8.12 Re-Assembly
The re-assembly of the operating head is of course in the reverse order of dis-assembly. Where
the operating heads are rotary soot blower, heads, care should be exercised when the head is
reinstalled that element flange is registered properly on the operating head. If some marks or
care is exercised in this respect it will save resetting the blowing cams in order to correct the
blowing arc.
Blowing arcs should be double checked on all rotaries after replacement to avoid cutting tube
destroying baffles or inducing improper cleaning that would be encountered if the blowing
arc were established in the improper segment or if the element is improperly moved end
ways.
Note: We recommend that the SB valve assembly to be sent to the factory for re-conditioning
rather than the customer trying to recondition the valve since special care should be taken in
repairing this valve.
9. RECOMMENDED PROCEDURE FOR PACKING INSTALLATION
The useful life of packing is dependent on the method of installation. Poor installation can
cause the best packing to fail prematurely. The methods in this procedure, if followed, will
lead to better sealing and longer life.
These packing method apply both to installing packing in new equipment and replacing packing
in equipment that is in service.

24
GO TO INDEX
1216 - 1217 VOL - C1 TAB - 4 - 60
9.1 Installation method
Clean out the old packing. Flexible packing hooks are available for removing the packing.
Inspect the feed pipe stem for wear or damage. Remove any raised metal that projects above
the normal surface. Do not try to file out depressions or scratches. Raised metal will tear
packing. Any reworking of scratches will only worsen the condition.
Keep the new packing clean during installation. Grit or other hard foreign matter that is
installed with the packing may score the feed pipe causing an early failure of the packing.
Install all packing rings so that the joints are staggered and kept approximately 90 Deg. apart.
Spot the joints in clockwise direction to facilitate locating them when removing the packing.
9.2 Install the rings one at a time
Each ring must be set firmly into place with either the gland or a tamping tool as shown in
figure. After each ring is installed, the ring must be compressed with approximately the same
force that it will have with the final gland force. Each ring should be equally compressed
when the entire set is installed. If this is not done, only the last ring will do the sealing and
will wear quickly.

Install each ring as per the figure.


Bevelled packing is to be installed with the bevel lip on the shaft pointing toward the pressure.
One end of the tamping tool is angled for bevelled packing. Fit the bevel on the packing to the
bevel on the tool see figure.
Oil or grease may be applied to the outside of braided asbestor packing to help in installing it
in the stuffing box.
Tighten the gland follower, sufficiently tight, after the packing has been installed to insure
final seating of the packing. The nuts should be backed off two or three turns to relieve
excessive pressure. Adjust packing to operating conditions.
Allow packing to leak a small amount, if possible, when starting newly packed equipment.
Tighten the gland slowly as the packing seats.
Do not be afraid to let packing leak a small amount. It is good assurance that packing is not
too tight and the liquid usually has some lubricating qualities.
When renewing packing, use all new clean packing. Worn packings are dry, highly compressed,
have high friction and may develop scoring. Remember packing is relatively cheap. Labour
and materials necessary to replace worn feed pipes are expensive and critical commodities.
The most expensive seal is a seal that fails.
Light gland pressure should be maintained at all times. Too much pressure will cause binding,
scoring of the shaft and force the lubricant out the packing. Too little gland pressure will
allow excessive leakage and washing out of the packing.
When the packing has been compressed to less than ¾ of its original height, it should be
replaced. The loss of height in packing may indicate a loss of essential lubricant.

25
GO TO INDEX
1216 - 1217 VOL - C1 TAB - 4 - 61
lAPPING TOOL

9.3 Packing
Keep packing glands just tight enough to prevent leakage : Do not overtighten them. Replace
packing that leaks excessively. Refer to instruction ‘Recommended Procedure for Packing
Installation’.
10. INSTRUCTIONS FOR STORAGE
All the Soot Blowers, though designed for outdoor applications, require special care during
storage before erection and commissioning. These instructions may please be taken seriously
to avoid costly replacements or breakdowns at a later date.
(i) On receipt of the Soot Blowers, carefully check for any damage of the components.
List out the damaged components with reference to the item no. in the concerned assembly
drawings to BHEL, Tiruchirapalli for further action.
(ii) See the Soot Blower assemblies are shipped completely covered with waterproof
coverings. Unless the blowers are taken for immediate erection please do not disturb
the coverings. Coverings are to be replaced wherever damaged.
(iii) Some assemblies like Wall Deslaggers and Rotary heads are shipped with temporary
wooden platforms to prevent parts getting damaged during erection. These need not be
removed till the blowers are erected.

26
GO TO INDEX
1216 - 1217 VOL - C1 TAB - 4 - 62
(iv) All the electrical items are to be covered with waterproof and dust proof coverings.
Nozzle and valve openings are shipped covered. This may be checked and covered
wherever necessary.
(v) Normally storage under covered roof is not necessary for Soot Blowers when the
waterproof covers are not removed. Wall Deslaggers and Rotary Soot Blower heads
can be stored under covered roof if the interval between Soot Blower erection and
receipt is more than two months.
(vi) Always use the lifting lugs or hooks provided to avoid damage to the connected parts.
Similarly avoid hitting the assembly against structures or other boiler components while
the Soot Blowers are being lifted.
(vii) The above instructions are for guidelines only and the concerned persons may use their
own discretion’s knowing well that these are electro-mechanical components.

27 Go To Pub Index
GO TO INDEX
1216 - 1217 VOL - C1 TAB - 4 - 63
TAB - 5

GO TO INDEX
INSTRUCTIONAL MANUAL
WALL DESLAGGER
MODEL-WB IE

Bharat Heavy Electricals Limited


Tiruchirapalli

PUB.NO.7503

GO TO INDEX
1216 - 1217 VOL - C1 TAB - 5 - 64
CONTENTS
INTRODUCTION
IMPORTANT INSTRUCTIONS FOR ERECTION,START-UP & OPERATION
DESCRIPTION
WALL DESLAGGER BASIC ASSY. (REF. DRG. 0-00-073-60026)
INSTALLATION
CHECK LIST AND ADJUSTMENTS
CHECK LIST
ADJUSTMENTS
START UP CHECKS
OPERATION
OPERATIONAL PROBLEMS AND MAINTENANCE
MAINTENANCE AND LUBRICATION
RECOMMENDED SPARES

2
GO TO INDEX
1216 - 1217 VOL - C1 TAB - 5 - 65
Wall Deslagger
LIST OF DRGS INCLUDED IN THE MANUAL

1. 0-00-073-60026 WALL DESLAGGER BASIC ASSY.


2. 0-00-073-60027 SWITCH BOX ASSY.
3. 1-00-073-60003. SBV HEAD ASSEMBLY
4. 1-00-073-60109 RACK GEAR HOUSING ASSY.
5. 1-00-076-60110 ROTARY GEAR BOX ASSY.
6. 2-00-073-60088 WALL DESLAGGER MAIN ASSY.
7. 3-00-073-60008 CAM ASSY. (TERMINAL BOX)
8. 3-00-073-60105 CLEVIS BRACKET ASSY.
9. 3-00-073-60006 WALL BLOWER WIRINGDIAGRAM
10. 3-00-073-60106 RACK CAM ASSEMBLY
11. 4-00-073-60165 SPECIAL ALLEN KEY
12. 4-00-073-60166 SPECIAL SQUARE KEY
13. 4-00-073-60167 VALVE SPRING TOOL

3
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1216 - 1217 VOL - C1 TAB - 5 - 66
INTRODUCTION

The coal fired boilers demand the maximum in effective Furnace wall slag control. Effective
deslagging entails- high striking power combined with barest minimum “dead time” between
blowings. WBIE Wall Deslagger is designed to efficiently meet these needs.
No soot blower system will operate satisfactorily if it is not properly installed, operated and
maintained. It must be recognised that no amount of written instructions can replace intelligent
thinking and reasoning on the part of the operators, especially when coping with unforeseen
operating conditions. It is the operator’s responsibility to become thoroughly familiar not
only with the equipment but also with all pertinent control equipment.
The instruction gives the general description of the wall deslagger and its installation
procedures. Details of the, adjustments of blowing speed, valve stroke and nozzle are outlined.
The operation, maintenance and lubrication details are also given.
The contents in the manual have been compiled and checked by experts in the field. Every
possible care has been taken to ensure the contents are accurate. However, it must be understood
that the manual is not a contract document.
If you ever have any query about operation, maintenance or related problems, you are welcome
to write to us without obligation.

BHARAT HEAVY ELECTRICALS LTD.


BOILER PLANT - TIRUCHIRAPPALLI.

4
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1216 - 1217 VOL - C1 TAB - 5 - 67
WALL DESLAGGERS
IMPORTANT INSTRUCTIONS FOR ERECTION,START-UP & OPERATION
DO’S
ERECTION
1 Check the opening in the boiler wall. It shall be minimum 75 mm through.
2. Check the wall sleeve for perpendicularity and concentricity.
3. Check blower number with reference to location drawing.
4. Check the ACCESSIBILITY FOR HAND CRANK and the Switch box assembly.
5. Check whether the WALL DESLAGGER is PERPENDICULAR after mounting.
6. Check the PROJECTION OF NOZZLE INTO THE WALL.
7. Support the SOOT BLOWER piping on the Boiler STEEL such as BUCK STAYS,
FURNACE GUIDES etc.
8. After the nozzle setting, PUNCH MARK on the alignment plate.
BEFORE START-UP
1. FLUSH the gear boxes thoroughly with ‘SERVOMESH 60’ and fill the gear boxes
with the lubricants as recommended.
2. Make sure the DRAIN HOLES in the MOTOR FRAMES point downwards and are
open.
3. Check the direction of rotation of both the MOTORS.
4. Make sure that the stop nuts are in place on the rods.
5. Check whether covers are put on the blower.
6. Check the perpendicularity of the blower when the blower is working.
START-UP AND OPERATION
1. Check Lubricating oil levels frequently.
2. Ensure all the interlocks are in use.
3. Ensure availability of hand cranks for immediate use.
4. Set the Blowing as per recommendation.
5. Ensure proper valve opening and close during operation.
6. Ensure the blowers are at home position after cycle completion.
7. Ensure a gap of 3-6mm between rotary gear box and rack gear guide rod boss at the
extended position.
8. Attend steam leakage immediately.
9. In case off emergency alarm due to elapsed timer, Low header pressure, No blowing
medium, A/C supply failure, interlocks, etc., immediately withdraw the swivel tube
using emergency hand cranks, after switching off the Power Supply.
10. Pay immediate attention of rectifying the mechanical and electrical faults.
11. Observe all the safety practices.

5
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1216 - 1217 VOL - C1 TAB - 5 - 68
DONTS
ERECTION
1. Do not place heavy Loads on wall deslagger.
2. Do not use the blowers as welding platform.
3. Do not remove the wooden supporting planks until soot. blower is firmly fixed to
wall.
4. Do not leave the swivel tube at extended position.
START-UP AND OPERATION
1. Do not operate wall deslagger with wet steam.
2. Do not operate the blower without blowing during boiler operation.
3 Do not attend any maintanence work on soot blowers when power and /or steam
supply is ‘ON’.
4. Do not operate the blower with excessive steam leakage through packing.
5. Do not use hand crank lever for retract when power is ‘ON’.
6. Do not stand near peepholes when the blower is operating.
1. DESCRIPTION
1.1 Wall Deslagger Basic Assy. (Ref. DRg. 0-00-073-60026)
The deslagger consists of a stationary body (item 10) and rack gear housing (item 2) and a
rotary gear box assy. (item 3) to which the swivel tube assy. (item 5) is attached. The swivel
tube assy, is supported by Bushing (item 17) at each end of the body casting. The horizontal
guide rods (item No. 09 of Drg. No. 1- 00-073-60109) are used to assure proper alignment of
the relay gear box assy.
A stationary electric motor (item 59) is situated on the right side of the. blower. This motor,
through a Rack gear housing Assy. operates a pinion which drives a horizontal rack assembly,
(item 11) the outer end of which is fastened to the rotary gear box Assy. (item 3).
When the Rotary gear box approaches the fully extended position a ramp cam (item 2) attached
to the free end of the rack (item No. 01, 3-00-073-60106) contacts a bearing surface, which is
a part of the clevis bracket Assy. (item 6) and pushes the valve stem assy. (item No.02 of drg.
No. 1-00-073-60003), admitting the steam to the swivel tube. When the blower is started the
rack pinion moves the rack (item 11) and rotary gear box towards the boiler. Operation of the
Rack gear housing causes rotation of a shaft extending out -from the rack gear housing into a
switch box Refer Drg. No. 0-00-073-60027. Located in this switch box are two cam actuated
limit switches. One cam holds limit switch LSTE in the open position when the blower is
fully retracted. Extending of the blower moves the cam allowing LSTE to close. The blower
is then under its own control.
Near the fully - extended position, the ramp cam strikes the lever that open the SBV head
valve. The second limit switch cam strikes the LSTS limit switch, which opens the circuit to
the traverse motor (item No. 59) and closes the circuit to the rotary motor (item 60).
The rotary motor is attached to the rotary gear box assy. When LSTS closes, the motor rotates
the swivel tube through a gear train.
When the blowing sweep is finished the cam assy. (item 7) on the swivel tube contacts and
rotates the arm on the limit switch LSTR. The traverse motor begins to retract the blower.
Near the fully retracted position the cam again opens the switch LSTE to haet the blower.
6
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1216 - 1217 VOL - C1 TAB - 5 - 69
CAUTION : Care should be exercised when operating the WB-IE with its guard assy. (item
9)and its holding nuts (item 30) removed. If, for any reason, the stop limit switch. (LSTE) is
not actuated during the retract portion of the operating cycle, it is possible for the rotary gear
box to overtravel and drop off the end of the guide rods.
If the rack should come free of the gear rack pinion drive, the cams for the limit switches will
require resetting.
The end of the worm shaft (item 7 Drg.No. 1-00-073-60109) is slotted so that a hand crank
can be inserted to allow manual operation of the blower. Be sure the power circuits are de-
energized before using this crank.
1.2 INSTALLATION
i. Wall Deslagger Sleeves
A wall blower is supported by four studs attached to the flange of a sleeve or wall
box inserted in the boiler wall.
ii. For steel - cased wall: Install sleeve as shown on application drawing. Be sure
elevation and vertical location are exactly as shown in the relevant contract drawing.
Sleeves are usual ly attached to waterwall tubes to maintain proper distance between the fully
extended nozzles and the tube surfaces. Application drawings show how to allow for movement
of a sleeve relative to the boiler wall.
Cut the proper size hole in the casing panel or plate. With sleeve and panel or plate positioned,
build wall around it as shown in the drawing. If the sleeve flange is shown welded to the panel
or plate, tack welds will be sufficient if they are one inch apart on each of the four sides
iii. Erecting the Soot Blower
With sleeve properly installed, lift the blower into position.
Make sure there are no obstructions in the path of the rotary gear box.
Slide blower forward, so that the four M20 studs on the sleeve flange fit into the four holes on
the boiler end of the blower body. Screw one jam nut tightly against each side of each hole to
give the blower firm’ support.
Unless otherwise specified on the job drawings, no other support is needed.
iv. Adjusting the Blower Position
The blower must be positioned so the relationship between the fully extended nozzle and the
boiler wall (or the waterwall tubes) is correct.
In the absence of a specific dimension on the drawings, set the centre line of the back nozzle
38 mm from the face of the wall tubes.
Adjust the blower in or out of the boiler by turning the stud nuts on the sleeve plate.
To check the location of the nozzle, the swivel tube and nozzle should be extended fully into
the boiler. The blower is completely assembled and if clear, is ready to operate once the power
has been connected properly. For directions on making the electrical connections and setting
switches, see the instructions below. Before extending the swivel tube and nozzle, make sure
there are no obstructions in the path of the rotary gear box.
V. Erection of Piping
When the piping is erected, great care should be taken to make up the inlet flanged joint
properly. No piping should be supported by the blower.

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Proper piping supports and guides should be used to prevent piping strain. When the com-
panion flange is attached to the pipe correctly and the gasket is intalled, the flange should
match property. Then add the flanges, studs and nuts. When the nuts and studs are removed,
the flanges should not spring apart or to either side, nor should the pipe exert an upward force
on the head.
Whenver wall boxes are attached to waterwall tubes (as is usually the case) the blower will
move with the tubes when the boiler expands and contracts.
All piping and electrical connections should be sufficiently flexible and have expansion loops,
etc., to allow for this movement and prevent severe strains from being exerted on the blower.
Refer to the application drawings for the amount and direction of any movement of the
blower.

CAUTION : Switch Box Assy. Refer Drg. 0-00-073-60027


When adjusting limit switches, power to the unit must be turned off to avoid injury of the
operator. Operation of the unit should be by means of the hand crank (item 11) provided.
The operation of the deslagger is controlled by three limit switches. Two of these (LSTE &
LSTS) are located inside the switch Box enclosure, mounted on the right side of the blower.
The thi rd switch (LSTR) is situated below the swivel tube and is operated by a split cam
(item 9) on the tube.
The setting of switches LSTE and LSTS are shown in the drawing referred above. The cams
operating the switches are set at the factory. Minor adjustment may be necessary. The inner
cam operates the LSTS switch, which starts the rotary motor. Ensure the Rotary gear box
stops 3 to 8 mm before the guide bar bush ( without ramming against the boss). The outer
cam operates stop switch LSTE and must be set to trip LSTE, and hold it open when the gear
box is 8 to 10 mm from the fully retracted or park position. When first operating the blower,
check this carefully. It must be so set to allow for drift after motor is shut off.
The inner switch cam for LSTS, must be set to trip the switch when the travelling gear box is
in between 3-6 mm from the fully extended position. This also should be checked when
running the blower for the first time.
Since packing friction affects the amount of drift, care must be taken to avoid ramming the
rotary gear box against the stops in either directions.

vi. Electric Connections


WIRING DIAGRAMS: Refer Drg. 3-00-073-60006
The electrical connections can now be made as shown on the application drawings. For
Blowers with integral terminal box, all wiring connections are made to the terminal box. For
blowers without integral terminal boxes all connections are still made to one point - the small
cast box on the top of the blower. The number of connections to be made are shown on the
wiring diagrams.
Before operating any blower, make sure the drain holes in the motor frames point downward
and are open. Add the proper quantity of oil to the two gear boxes (rotary and traversing) and
assure that the vents point up and are open.

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1216 - 1217 VOL - C1 TAB - 5 - 71
2. CHECK LIST AND ADJUSTMENTS
2.1 Check List
i. Lubrication
a. Rotary gear box
b. Traverse gear box
ii. External Electrical connections
iii. Nozzel position adjustment
iv. Perpendicularity of swivel tube with respect to furnace wall.
v. Pressure setting
a. Initial setting
b. Final setting
vi. Limit switch adjustment for rotary gear box travel
vii. Removal of SBV head NRV plug.

2.2 Adjustments
i. Adjustment of Blowing Sweep
The sweep of some wall blowers is restricted because of their proximity to corners or
burners. Refer to the application drawings to determine sweep.
It is important that the sweep be set as closely as possible to that shown on the application
drawings, otherwise damage to the boiler may result.
The nozzle opening position is indicated by a mark on the swivel tube or by the key slot in
the swivel tube which can be seen by, removing the guard and the nut and washer at the end
of the swivel tube. To adjust the sweep, remove the sheet metal guard. If it is convenient to
operate the blower with electrical power use the “local start” push button station. The swivel
tube and rotary gear box extend rapidly; be sure there are no obstructions in the path of the
rotary gear box.
To stop the swivel tube rotation and retract the tube and gear box, rotate the lever on the
reverse limit switch operated by the split cam on the swivel tube. This will retract the blower
rapidly. Make sure there are no obstructions in the path of the rotary gear box
On standard wall blowers there is one stop collar or split cam on the swivel tube, (item 7)
adjacent to the rotary gear box (item 3).
This collar contacts the lever of the reverse limit switch to retract the blower at the end of its
sweep. On wall blowers with restricted sweeps there are two cams. One cam contacts the
limit switch to reverse the swivel tube at the end of the sweep, while the other retracts the
swivel tube and rotary gear box at the end of the blowing sweep. Loosen the set screws in
these cams and assure that they are loose on the swivel tube before adjusting the sweep. To
adjust the sweep, start the blower and allow the swivel tube to rotate until it is in the proper
position for the end of the blowing sweep. Retract the swivel tube, using the reverse limit
switch. Set the reverse limit switch stop collar so that the side of the collar will just contact
the side of the reverse limit switch lever. Tighten the setscrew.
With all adjustments completed, operate the blower and check the sweep for correctness,
preferably from inside the boiler. Replace the guard (item 9).

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1216 - 1217 VOL - C1 TAB - 5 - 72
ii). Valve Stroke Adjustment
SBV HEAD ASSY: Refer Drg. 1-00-073-60003
The SBV head allows the blowing pressure of the blower to be adjusted by limiting the stroke
of the head valve. Where it is necessary to reduce pressure greatly, a fixed orifice may be
installed in the head inlet flanges.
The stroke of the head valve is governed by adjustment of the drive screw which contacts the
head valve stem. In the closed position, a minimum clearance of 1 mm must be maintained
between adjusting screw and valve stem, to assure tight valve seating.
In general, slag removal will necessitate blowing pressure of 10-14 kg/sq cm. Soot and fly ash
will need 10-18 kg/sq cm and dust removal pressure may be as low as 7 kg/sq cm. Always
consult the General Arrangement Drawing for recommended blowing pressure.
The stroke of the head valve is governed by adjustment of the drive screw which contacts the
head valve stem. Maximum stroke of the valve is 14.5 mm. If this maximum stroke is desired
adjust the valve drive screw so the screw begins to depress the valve stem when the pad on the
rotary gear box is 38 mm from the rack housing pad. When these two pads touch, the rotary
gear box is fully extended. Extending the screw through the lever increase valve opening and
blowing pressure. In the closed position, a minimum clearance of 0.8 mm must be maintained
between the drive screw and the valve stem, to assure tight valve seating.
When proper pressure has been established, by gauge reading, lock the drive screw in place
with lock nut.
iii. Nozzle Adjustment
Nozzle alignment should be made from inside the furnace, referencing the centreline of the
nozzle and wall tube surface, with the nozzle opening parallel to the wall tubes. If the units
are set from outside the boiler, they should be checked inside at the first opportunity.
After the unit is installed, it should be checked to make sure that it is perpendicular with the
boiler wall, to insure cleaning through the full blowing arc.
The sweep should then be set, if possible, so that the nozzle is pointing down or in the 6
O’clock position, when the head opens. This helps to prevent tube cutting from condensate
since the nozzle blows parallel with the tube when the head first opens and condensate is
blown off before the jet sweeps across tubes.
3. START UP CHECKS
For detailed Start up checks
a. Check the blower numbers and their location.
b. Check the perpendicularity of the wall sleeve with reference to water wall
c. Check the mounting of the blower for perpendicularity to the water wall.
d. Ensure the nozzle projection inside the boiler. (Normally the nozzle centre line
should be 38 mm from water tube).
e. Check the free manual movement.
f. Check whether all the blowers are in the initial position.
4. OPERATION
When just putting the blower into service, start it locally so that the operation of all parts can
be observed. It is advisable to check the blowing pressure, using an auxiliary gauge. Start the
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1216 - 1217 VOL - C1 TAB - 5 - 73
unit and observe to confirm that the blowing steam comes on at the proper time. If not, hand
operate the blower reversing switch LSTR. If the boiler is in operation do not allow the
blower extended for any length of time as the swivel tube may get damaged. If the valve head
has failed to open, retract the blower before examining the head.
There is a panel start push button for each blower. Each button should be held in about three
seconds, then released. The blower then extends, open the head, completes a blowing cycle,
closes the head and retracts. Operate each Push button once for each blowing cycle.

5. OPERATIONAL PROBLEMS AND MAINTENANCE


Problem Causes Suggested Remedy
1.Steam leakage through 1. Improper tightening Tighten the glands (Do not
swivel tube gland packing over tighten)
2. Excessive wear on the Replace the glands with
glands packings
3. Scratch marks, dents for In case excessive surface
surfaces defect on the defect change the swivel
swivel tube tube
4. Defective packing or poor Replace the defective
quality of packing packing
2. Traverse Motor over 1. Physical obstruction to Observe for any obstruction
loading gear box assy. and clean
2. Dust deposition on swivel Clear the dust and debris
tube, guide rods using compressed air
3. Overtightened gland Maintain proper tightness of
packing packing rings
2. (a) Gear box assy. not 1. Overtightening of swivel A slight amount of steam
moving tube packing passing is advisable for
ensuring proper tightness
2. Defective surface Replace the swivel tube
condition of swivel tube

3. Valve stem seizure Service the valve head


adjust valve stem packing
tightness
2. (b) Motor over loading at 1. Limit switch LSTS Reset the cam in limit
extended position improper setting switch box
2. Improper setting of O/L Check the setting and do
relay at MCC the connection
3. Accumulation of slag Clear the slag accumulation
inside the sleeve tube.
3. Steam leakage through 1. Poor defective packing Use good quality packing
valve stem

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1216 - 1217 VOL - C1 TAB - 5 - 74
Problem Causes Suggested Remedy

2. Defective surface Check the condition of valve


condition of valve stem and gland bushing and
stem/gland bushing replace the defective one
3. Inadequate tightening of Tighten the packing rings
packing rings (Do not over-tighten the
packing)
4. Valve passing: (through 1. Gland packing over Slightly loosen the gland
bushing
seat) tightened so that the stem is not
tightly held by the packing
2. Insufficient lapping or Dismantle the valve Disc
improper lapping or and seat using lapping tool
damaged valve disc (As suggested in Pub. No.
7501) for severe damages
either in disc or seat replace
the damaged part.
3. Foreign material trapped This will be cleared when
in between disc and seat the valve is wide opened.
6. MAINTENANCE AND LUBRICATION
1. General
Soot blowers, nozzles and swivel tubes are continuously subjected to high temperatures and
dirty atmosphere. Therefore, proper maintenance is necessary to keep this equipment as trouble
- free as possible. To assure efficient operation and long life, attention must be given to the
item below
a. Cleanliness
To assure long life and good performance of soot blowers, the outer surfaces should be cleaned
of dirt and rust periodically. If allowed to accumulate, dirt and rust will enter the operating
mechanism, prevent proper operation and cause excessive wear on moving parts. If a blower
is not to be used for appreciable time, coat all exposed surfaces with a good grade of grease.
b. Equipment Inspection
A regular check, at least every six months should be made for wall deslaggers while the boiler
is on service to ensure that the wall blowers remain perpendicular to the boiler wall. Pipe
strain and boiler movement can after the position of these units in such a manner that, the
swivel tube is not perpendicular to the surfaces of the wall being cleaned. This check is necessary
to prevent tube erosion and it can be made visually or by placing a spirit level on the rack of
swivel tube. Correction is accomplished by adjusting the nuts on the studs of the wall box
adaptor where the stud passes through wall deslagger steam chest mounting flange.
Check the distance from the centre line nozzle to the surfaces to be cleaned. This distance
should be given in arrangement drawing issued for the relevant contract. Normally the distance
will be 38 mm.
Mounting : Check the soot blower mounting periodically to make sure the blower is securely
mounted and properly adjusted. The mounting position is adjusted by means of the stud nuts
on the sleeve. Be sure each nut on each side, of the blower body flange is tight. Loose mounting

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1216 - 1217 VOL - C1 TAB - 5 - 75
or improper adjustment may result in misdirection of the blowing medium and possible poor
cleaning or boiler damage.
Piping : Check the external piping periodically for leaks. Tighten fittings to stop leaks or
replace faulty fittings and connections. Be sure the piping places no strain on any blower.
Swivel Tube Nozzle : At every boiler outage an inspection should be made of each swivel
tube nozzle. If a nozzle is split or cracked, it should be replaced.
Blowing Sweep : Any blower with a sweep of less than 360 deg. should be checked periodically
for adjustment. The sweep should be kept the same as that on the application drawings. It is
also advisable to check adjacent boiler tubes and walls for any possible damage.
ii. Lubrication
a. Rack Gear Box : Every six months remove the inspection plug and make an inspection
for sufficient lubrication of the gears. Apply the lubricant directly to the gear box.
Use 0.6 lit. of Servomesh 60 or equivalent poured through the inspection opening.
The oil level plug is small brass pipe plug on the front of the box about 50 mm from
the bottom.
b. Rotary Gear Box : Every six months make an inspection for sufficient lubrication
of the gears at the combination inspection and filler fitting. The lubricant is Servomesh
60 added through the combination filler and level elbow on the side of the box.
For detailed lubrication instruction refer to “Lubrication Chart and “Recommended
quantity of Lubricants per annum” in the publication No. 7501 : Soot Blower -
General Instructions.
iii. Packing
See Recommended Procedure for Packing Installation in the Publication No. 7501 Soot Blower:
General Instructions.
iv. Swivel Tube Removal
Removal of swivel tube will be necessary because of:
a. Cracked or damaged nozzle.
b. Persistent steam leakage even with new packing set due to swivel tube surface defects.
In order to remove the swivel tube, the main guard (item 9 of Drg. 0-00-073-60026) and the
rotary gear box are the only part that have to be removed. These two parts can be dismantled
without distrubing the Wall Deslagger assembly or any other pressure parts.
To dismantle the rotary gear box, the lock huts (item Nos.30,35 of Drg. No. 0-00-073-60026)
fixing the rack and ~the swivel tube to the rotary gear box should be removed and then the
gear box can be dismantled. After removing the rotary gear box the swivel tube assembly can
be pulled out of the Wall Deslagger body. The limit switch cam assembly shall be removed so
that it can be reused in the swivel tube assembly.
The procedure has to be followed in the reverse order for the assembly of new swivel tube.
For the Wall Deslagger with long extended swivel tube, the full assembly itself should be
removed from the mounting sleeve.
V. Spares
While ordering spares, indicate Item No., Drg. No., BPS No. as found in Bill of materials in
addition to the old contract No. etc. for early delivery.
In the enclosed drawings spares that are recommended for stock bytheuser are marked by “S”.
Section 7 gives the recommended List of Standard Spares.
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1216 - 1217 VOL - C1 TAB - 5 - 76
7. LIST OF RECOMMENDED SPARES FOR WALL DESLAGGER WB - 1 E
NOTE The list of spares under is to aid the selection of the required item.The editing and
deletion of number of pieces solely lie on the user.

Sl.No Description Item Assembly Part Material No. of WB - IE


No No Drawing No. Code 1-6 7 - 16 17 - 24 25 - 40 over 40
1. Valve gland Packing 12 2-00-073-60088 963533150000 4 8 12 16 20
set
2. * Packing set 11 2-00-073-60088 9653533180000 4 8 12 16 20
(Steam)
3. Gland 16 0-00-073-60026 160133990000 3 6 9 12 20
4. Bushing 17 0-00-073-60026 160134080000 3 6 9 12 20
5. Bearing SKF 6205 45 1-00-073-60109 55/119/0620500 2 4 6 8 10
2RS
SKF 6204 46 1-00-073-60209 55/111/0620400 2 4 6 8 10
Mc Gill CYR 13/8 12 3-00-073-60105 97/353/3130000 2 4 6 8 10
SKF 51101 31 1-00-073-60110 55/211/5110100 2 4 6 8 10
SKF 51102 32 1-00-073-60110 55/211/5110200 2 4 6 8 10
6. Motor (Rotary) 60 0-00-073-60026 962720730000 1 2 3 4 5
7. Motor (Traverse) 59 0-00-073-60026 962720050000 1 2 3 4 5
B. SBV Head Assy. 01 0-00-073-60026 84202010010 1 2 3 4 5
9. Oil Seal 17 0-00-073-60027 96/353/0830000 2 3 6 7 8
10. Oil Seal 37 1-00-073-60109 96/353/0820000 2 3 6 7 8
11. Limit Switch Heavy 18 0-00-073-60027 963582820000 2 3 6 7 8
duty
TVA5
12. Limit Switch (Micro) 03 0-00-073-60027 96/362/0640000 2 3 6 7 8
13. Limit Switch (Micro) 03 0-00-073-60027 96/362/0630000 2 3 6 7 8
14. Gaskets
Element Gasket 18 0-00-073-60026 963533590000 1 2 3 4 5

Sl. Description Item Assembly Part Material No. of WB - IE


No
No Drawing No. Code 1-6 7 - 16 17 - 24 25 - 40 Over 40
Motor Gasket 49 0-00-073-60026 96/353/113 1 2 3 4 5

Cover Gasket 42 1-00-073-60109 96/353/046 1 2 3 4 5


Gasket 50 0-00-073-60026 96/353/047 1 2 3 4 5
Gasket 43 1-00-073-60109 963530540000 1 2 3 4 5
Cover Gasket 12 0-00-073-60027 96/353/112 1 2 3 4 5
Gasket 05 1-00-073-60003 22/021/303 1 2 3 4 5
Gasket 09 1-00-073-60110 96/353/044 1 2 3 4 5
Gasket 09 2-00-073-60088 22/021/269 1 2 4 6 8
15. Swivel tube 05 0-00-073-60026 842020125500 - 1 1 2 2
Assy.

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TAB - 6

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FURNACE TEMPERATURE
PROBE
MODEL FTP IE & IIE

Bharat Heavy Electricals Limited


Tiruchirapalli

PUB. NO. 7505

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1216 - 1217 VOL - C1 TAB - 6 -92
CONTENTS
INTRODUCTION
GENERAL
GENERAL DESCRIPTION
GENERAL
DETAILED DESCRIPTION
POWER PACK ASSEMBLY
THE TRAVELLING CARRIAGE
LANCE ASSEMBLY
POSITION INDICATOR
CONTROL CIRCUITRY
INSTRUCTIONS FOR INSTALLATIONS
INSPECTION CHECK LIST
INSTRUMENTATION WIRING
OPERATION
THREE PUSH BUTTON OPERATION (LOCAL AND REMOTE)
EMERGENCY RETRACTION
REMOTE POSITION INDICATOR
MAINTENANCE INSTRUCTIONS
LUBRICATION
REPLACEMENT
THERMOCOUPLE REPLACEMENT
POTENTIOMETER REPLACEMENT
RECOMMENDED LIST OF SPARES FOR TEMPERATURE PROBE
REQUIRED TOOLS FOR TEMPERATURE PROBE
RECOMMENDED LUBRICATION CHART

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LIST OF DRAWINGS
(WITHOUT AIR COOLING)
0-00-073-60028 FURNACE TEMPERATURE PROBE BASIC ASSY.
0-00-073-60004 POWER PACK ASSEMBLY - TRAVERSE
1-00-073-60112 LANCE BEARING ASSEMBLY
2-00-073-60006 WIRING DIAGRAM
2-00-073-60092 TRAVELLING CARRIAGE HOUSING ASSEMBLY
2-00-073-60091 FURNANCE TEMP. PROBE MAIN ASSY.
2-00-073-60093 STOP LIMIT SWITCH ASSEMBLY
2-00-073-60094 REVERSE LIMIT SWITCH ASSEMBLY
3-00-073-60107 LANCE ASSY.
3-00-073-60108 DRIVE JACK SHAFT BEARING ASSEMBLY
3-00-073-60109 IDLER JACK SHAFT BEARING ASSEMBLY
3-00-073-60110 POTENTIOMETER ASSEMBLY
3-00-073 60001 THERMOCOUPLE ASSEMBLY
4-00-073-60005 TRAVERSE CHAIN ASSEMBLY
4-20-001-00523 CHAIN ADJUSTMENT
4-00-073-60110 REQUIRED TOOLS FOR FURNACE TEMPERATURE PROBE

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LIST OF DRAWINGS
(WITH AIR COOLING)

0-00-073-60029 POWER TRACK FURNACE PROBE ASSY. (WITH AIR COOL-


ING)

1-00-073-60128 B.O.M. FOR FURNACE TEMP. PROBE BASIC ASSY.

0-00-073-60004 POWER PACK ASSEMBLY - TRAVERSE

1-00-073-60112 LANCE BEARING ASSEMBLY (FOR 76mm O.D. LANCE ONLY)

2-00-073-60096 SOLENOID VALVE ASSEMBLY

2-00-073-60097 LANCE ASSEMBLY

2-00-073-60098 TRAVELLING CARRIAGE HOUSING ASSEMBLY

2-00-073-60093 STOP LIMIT SWITCH ASSEMBLY

2-00-073-60094 REVERSE LIMIT SWITCH ASSEMBLY

3-00-073-60123 COOLING AIR LIMIT SWITCH ASSEMBLY

3-00-073-60124 CYCLING LIMIT SWITCH ASSEMBLY

3-00-073-60108 DRIVE JACK SHAFT BEARING ASSEMBLY

3-00-073-60109 IDLER JACK SHAFT BEARING ASSEMBLY

3-00-073-60110 POTENTIOMETER ASSEMBLY

3-00-073 60001 THERMOCOUPLE ASSEMBLY

3-00-073-60125 PUSH BUTTON ASSEMBLY

4-00-073-60005 TRAVERSE CHAIN ASSEMBLY

4-20-001-00523 CHAIN ADJUSTMENT

2-00-073-60099 PHYSICAL WIRING DIAGRAM

3-00-073-60127 SCHEMATIC WIRING DIAGRAM

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INTRODUCTION
The Furnace temperature probe installed in various power station installations is manufactured by
BHEL with its Engineering know-how and the sum of the experience gained on many new installations
in India. The BHEL Furnace probe gives the reach needed for a constant check on gas temperatures
in critical boiler start-up phases and provide an extra measure of protection during periods when
boiler equipment is subject to the most hazard. The temperature measurement system will function
satisfactorily with a little attention to installation, operation and maintenance.
It must be recognised that no amount of written instructions can replace intelligent thinking and
reasoning on the part of the operators, especially when coping with unforeseen operating conditions.
It is the operators responsibility to become thoroughly familiar not only with the equipment but also
with all pertinent control equipment.
The instruction contained in this manual is only an outline of the correct procedures for installation,
operation and maintenance. The contents in the manual have been compiled and checked by experts
in the field. Every possible care has been taken to ensure the contents are accurate. However, it
must be understood that the manual is not a contract document.
If you ever have any query about operation, maintenance or related problems you are welcome to
write to us without obligation.

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GENERAL
This standard BHEL furnace probe is equipped with chromel alumel thermocouple installed in a
lance tube. Air cooling for the lance tube is also available for special applications.
Model FTP-IE for travels from 1.5 metre to 7.3 metre, has a 76mm O.D. lance. Model FTP-IIE
for travels from 7.4 metre to 12.2 metre has a 108mm O.D. lance.
In both the models, probes are available with or without air cooling.
The probe may be operated in furnace gas temperature upto 537°C (100°F) and for very short
period of time in gas temperature as high as 565° C (1050°F) without air cooling.
The temperature probe can be used to measure furnace gas temperature upto max. 815°C (1500°F)
with the lance cooled by air.
This standard equipment will be limited to monitoring furnace temperatures upto, but not exceeding
815°C (1500°F) during boiler start-up. While using for temperature above 565°C (1050°F), air
cooling of the lance probe must be used.
Cooling air requirement for the temperature probe is determined by the diameter of the lance, length
of travel and the temperature of the area in which the probe is expected to operate. Operators are
requested to observe four important limiting factors in the operation of standard furnace temperature
probes.
i. Never exceed 537°C (1000°F) without cooling air for continuous operation.
ii. Never exceed 565°C (1050°F) for short intermittent periods without cooling air.
iii. Never exceed 815°C (1500°F) with arrangement for cooling air.
iv. Ensure availability of sufficient cooling air.
Contact Engineering Division of Bharat Heavy Electricals Limited, Trichy for information concerning
specific applications and operations.

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2. GENERAL DESCRIPTION
2.1 GENERAL
The BHEL Furnace temperature probe is an electro-mechanical equipment for positioning a ther-
mocouple element in the furnace gas stream for temperature measurement. The thermocouple is
fixed to the tip of a lance tube which travels into and out of the gas passage. The lance travels
approximately two metres per minute while extending and retracting. The thermocouple can be
retracted manually in case of emergency.
Gas temperatures in the area just before the superheater elements at the exit of the furnace, can be
critical during boiler start- up, before steam circulation for the cooling of the superheater/reheater
tube material is sufficiently established. The furnace temperature probe, by permitting continuous
measurement of the gas temperatures, helps to reduce the danger of heat damage to the tubes. For
this reason, such probes are also known as basic start-up probes.
The furnace temperature probe can also be used to obtain gas temperatures during the low load
operation of the boiler.

2.2 DETAILED DESCRIPTION


Ref. Assembly drawing of temperature probe: (Drg.No.0-00-073- 60028 & 0-00-073-60029)
i. Probe Housing (Item No. O1/03 of Main assembly drawing as above.
The housing of the temperature probe is a pressed steel section and it covers all the moving parts.
The lips are cut off from the outboard end to a distance of approximately 750 mm to facilitate
removal of travelling carriage. Angle tracks are welding on either side of the casing to guide the
travelling carriage. The rods are provided at the bottom to hold the open ends of the housing. At the
front end a wall plate is welded on to the casing, to which the lance bearing assembly is fixed. The
lance bearing assembly carries an hour glass shapped roller for supporting the lance tube and a plain
cylindrical roller on top for guiding the lance. The mechanical stop for the carriage is also welded to
the housing top in the front. The stop at the outboard end is adjustable and is provided in the side of
the housing. The jack shaft bearing assembly which is fixed to the housing provides for the adjustment
of the tension in the traversing chain.4
A cable carrier drag chain (Item No. 42/36 of Drg.No. 0-00-073- 60028 & 0-00-07360029
respectively) is attached with travelling carriage, by the driving end and the fixed end of the drag
chain is connected with a mounting bracket assembly on the middle bottom of the housing. This drag
chain is supported by the track covers hanging from the housing on both right and left side and
guided by two angle plates on the bottom cover. The thermocouple lead wire is taken through the
drag chain support plates and connected to the terminal head near the mounting bracket assembly.
When provision for air cooling of the lance tube is made, an air hose is also taken through the
support plates of drag chain from the mounting bracket assembly to the travelling carriage housing
and it is connected with connectors at the both ends.
A ball valve with pneumatic actuator and a solenoid valve is mounted near the mounting bracket
assembly with a pressure switch. The hose pipe is connected to the outlet side of ball valve and inlet
side is the customer air connection (7 Kg/Cm²(g)).
Lifting eyes for sling attachment are welded to the side of the housing at convenient places, to
facilitate lifting. The probe is supported at two places. The boiler end is supported in the wall box
through two shoulder bolts which allow the probe to move when the wall moves. The outboard end
again is hinged support and is fixed to the boiler structures.

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ii. POWER PACK ASSEMBLY (01 of assembly Drawing No. 0-00-073- 60004)
The main prime mover for the probe is a fractional horse power motor. A reduction gear box
attached to the motor has an output speed of 9.2 rpm. The motor with the reducer is fixed on top of
the housing at the front end. The reducer output shaft drives the jack shaft through a set of sprockets
and an endless chain. The jack shaft transmits the rotary motion to a long chain for the entire length
of the probe, the ends of which anchored to the travelling carriage, through another jack shaft and
idler sprocket at the other end of the housing. The idler jack shaft is provided with adjusting screws
for keeping the chain in the right tension.
iii. The Travelling Carriage. (Drg.No. 2-00-073-60092 and 2-00- 073-60098)
The travelling carriage of the probe is a cast iron housing to which the lance tube is bolted. The
carriage assembly has two wheels which are guided by the inner side of the housing and the top of
guide angles. Two rollers on the sides of the travelling carriage prevent the sideways movements.
The travelling carriage guide rollers at the side also operate the arms of the terminal limit switches of
the heavy duty type which are fixed to the sides of the housing. Removal of the travelling carriage
assembly is achieved by unscrewing the removable portion of the angle guide track at the outboard
end and slipping the assembly down carefully without causing damage to the thermocouple at the
lance head.
In case of air cooled temperature probe, the travelling carriage is made, up cast steel/Ductile iron in
order to maintain pressurised chamber and a hose connector is screwed on the carriage to couple
the hose with it. (Ref.Drg.No. 1, 2-00-073-60098)
iv. Lance Assembly (Drg.No. 3-00-073-60107 & 2-00-073-60097)
The lance tube Assembly is bolted to the travelling carriage and the lance is a alloy steel tube. The
lance tube is not normally air cooled, when the probe is used for gas temperatures upto 537°C
(1000°F). If air cooling is provided, the air house is connected to a coupling at the travelling carriage
end of the lance tube.
The thermocouple is normally of the grounded chromel alumel type enclosed in a stainless steel
sheath. It is fixed to the end of the lance tube, by means of a threaded coupling. The thermocouple
extends through the lance tube to the terminal coupling at the carriage end where a female connector
for the lead wires is provided. The corresponding male connector is connected to the thermocouple
lead wire which terminates at the thermocouple terminal head, fixed on the housing, through cable
drag chain. The probe has to be connected to a suitable temperature indicator which will show the
gas temperature.
For preventing any damage to the thermocouple head a cage type protective shield is provided, and
this will allow free access of flue gases to the tip of thermo couple during operation. In case of air
cooled probe, an inner S.S.tube called lance liner tube is supported by equidistant lugs as shown in
the drawing 2-00-073- 60097 at various intervals inside the lance tube and two straight bore nozzles
are provided to expand the entering air pressure to furnace pressure. The air enters through the
annular space between liner tube and lance tube and enter the liner tube through the gap provided at
the front end to reach the nozzles thereby it maintains the cooling effect on the surface of the lance.
V. Position Indicator (see assembly drawing)
In order to know the position of the lance tube, corresponding the gas temperature, a position
indicator is normally provided with the temperature probe. The position indicator is a voltmeter
calibrated to continuously indicate the position of the thermocouple in. The voltmeter is connected in
parallel with a linear, ten turn helipot potentiometer (variable resistor) which is driven by a no slip
belt drive on the jack shaft. The mechanical arrangement of the potentiometer drive is illustrated in
Drg. 3-00-073-60109 and 3-00-073-60110.

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The details of the electrical wiring for the probe without air cooling are illustrated in the Drg.
2-00-073-60006 and for the probe with air cooling refer drawing 2-00073-60099 and 3-00-073-
60127. A 0-10 voltmeter calibrated in percentage of travel and at toroidal type 12k ohm. 50 watts
variable resistor are supplied loose, as position indicating instruments along with the probe. The
voltmeter and the variable resistor are to be mounted in the control cubicles and wired to the helipot
poten tiometer by the customer. The variable resistor is to be used for calibrating the travel indicated
by the voltmeter. The calibration of the position indicator is to be done during commissioning of the
temperature probe. 110V single phase 50 cycle is recommended for this circuit.
Vi. Control Circuitry
The control circuitry on the temperature probe is designed as per the requirement. All electrical
hardwares for control and indication are subject to the customer’s option. For this reason, control
arrangements are presented in detail by specific contract circuit descriptions and contract drawings.
3. INSTRUCTIONS FOR INSTALLATIONS
3.1 Inspection check list
i. Check the thermocouple tip for any damage from handling or shipment, after removing
the shield for the thermocouple.
ii. Check all control and power wiring for loose terminals, proper connections etc.,
iii. Check connection of motor for proper direction of rotation.

iv. Check all thermocouple junctions for tight terminal connections.


V. Check the limit switch actuating arms to see that they are in correct operating positions.
vi. Check alignment of frame structure, track and sheave wheel track, particularly for any
bend, twist or other distortions.
vii. Check roller chain sprockets for correct engagement with the chains.
viii. Check alignment of the roller bearing for the lance tube and adjust only, if required.
ix. Check lubrication of roller chains, sprockets bearings, wheels, rollers, etc., and fill in oil
for the reduction gear of the power pack.
x. Check for pressure tightness of the air hose reel, if the probe is provided with air cooling
arrangement.
3.2 Instrumentation wiring
The thermocouple lead wires are internally connected to the fixed terminal head on the probe during
manufacture. The extension wire should be taken from the terminal head. Ensure the use of the
correct compensating cable corresponding to chromel/Alumel thermocouple, the leads connecting
to the indicating instrument should be connected to the junction head according to the polarity
indicated by the marking of the terminals and the code markings on the leads. Ensure that all
connections are tight and firm. A potentiometer type instrument is recommended as the temperature
indicating device.
NOTE : Check connections of measuring instrument, position transmitter etc., for proper polarity.
4. OPERATION
Refer to the contract circuit diagram for the correct operating description.
4.1 Three push button operation (local and remote)
This push button station has ‘Extend’, ‘Retract’ and ‘Stop’ push buttons. By operating the ‘Extend’
push button the forward contacts of the drive motor will be energised and the probe will move

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forward. Normally, approximately 35 seconds lag is expected between the thermocouple position
and the corresponding thermocouple temperature. If multipoint recorder is used, the lag will increase.
If the temperature registered by the probe is below 538°C it is expected to be within approximately
50C to the actual temperature measured at the location.
The position transmitter will indicate to the operator the travel of the probe in percentage of full
travel.
At the end of the travel, the travelling carriage side thrust roller will actuate the reverse limit switch
and then the ‘reverse’ contactor will be energised to reverse the drive motor and retract the probe.
An indicating ‘red’ light may be connected in the panel which will momentarily indicate when the
reverse limit switch is actuated.
If required with a change in the circuit the probe may be stopped at the full extended position when
the reverse limit switch is actuated. Indicating light can be suitably connected to indicate full extended
position as red light in the panel. When the ‘reverse’ push button is operated the probe reverses
from any position and when the stop limit switch is actuated the probe stops at the fully retracted
position and a green light will come on the panel. In the intermediate position both lights will be off.
By utilizing the ‘STOP’ push button, the probe lance can be stopped at any desired location. This
will enable the operator to check and concentrate on any hot spots in the furnace.
A remote contact on the temperature recorder which will close when the temperature measured is
+300C more than the maximum 538°C is necessary to give an alarm; and the same time the probe
can be retracted.
A parallel push button station in the panel will be necessary for remote operation.
4.2 Please refer to application and wiring diagrams (Drg.No. 3-00-073-60127)
This BHEL Furnace Temperature Probe is equipped with a duplex Chromel-Alumel Thermocouple
either duplex or simplex. The equipment is limited to monitoring furnace temperatures upto, but not
exceeding 1000°F without cooling air; and up to, but not exceeding 1500°F with cooling air. Confirm
that sufficient cooling air is available. Operators must observe the temperature limitations to avoid
damage to, or loss of, the lance. Contacts (RC) on the customer’s recorder are to close when the
temperature reaches 1500°F, energizing the RA relay which will cause the probe to retract to its AT
REST position and bring in the customer’s alarm.
The temperature probe controls include PARK, EXTEND, RETRACT and STOP push buttons, a
solenoid valve SV, pressure switch PS (opens on flow), timer T, alarm relay RA and relay P. (Please
note the following are not by PS 20 Group; Alarm relay RA, and Relay P).
Solenoid Valve SV and timer T will be energized when the blower moves away from its PARK
position and actuate Limit Switch LS-4. SV, PS and timer T form the cooling air supply interlock. If
cooling air is not sensed within the time relay period (10 seconds), relay RA will be energized to
bring in the alarm. The probe will be caused to retract to its PARK position. Loss of cooling air
during operation will also energize the alarm relay.
The control push button function as follows:
EXTEND - Depress this push button to cause the probe to extend into the boiler.As the
probe moves away from its AT REST position, it will trip LS-3 and LS-4 limit
switches. When the probe reaches its fully extended position, it will momentarily
trip limit switch LS-1 causing the probe to retract. This circuit will be through
closed RET and LS 3 contacts to the RET motor starter.
RETRACT - Depress this pushbutton to cause the probe to retract to its fully retracted position.
The probe will not remain in its fully retracted position, but will be caused to extend as it momentarily

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trips limit switch LS-2, creating a circuit to the EXT motor starter.
STOP - Depress this pushbutton to stop the probe, at any position, on the EXTEND or
RETRACT cycle, to take a reading to continue the EXTEND or RETRACT
cycle, depress the desired pushbutton to reinstate the circuit.
PARK - Depress the pushbutton to cause the probe to return to the fully retracted position
and stop. The probe will also be caused to PARK if the RA alarm is brought in.

4.3 Emergency Retraction


Using a hand crank, the lance can be retracted manually in case of emergency. Before using the hand
crank the power supply to the drive motor should be disconnected and the drive should be declutched.
For declutching pull out the coupling item 05 of Drg. 3-00-073- 60108 and turn about 900 clockwise
thereby the spring lock provided will lock the coupling in the declutched position. For clutching just
turn the coupling lock 900 anticlockwise which will keep the coupling engaged with sprocket. A
slight adjustment of the sprocket may be necessary in some cases to align the clutch jaws with the
sprocket.

4.4 Remote Position Indicator


Setting and Installation Instructions for the slidewire Type position Indicator.
CAUTION: The voltmeter indicator is built to accept a maximum of ten (10) volts only. There-
fore, it will be necessary to use a separate test voltmeter with a scale suitable for the maximum
incoming control voltage.
i. Refer to BHEL Wiring Diagram.
ii. Mount the adjustable resistor as near as possible to the voltmeter indicator.
iii. WITH POWER OFF connect all wires as shown on the W/D except the two on the
voltmeter indicator; connect these two to the test meter, (see caution above).
iv. Move the slider of the adjustable resistor to the extreme opposite end of the resistor from
the power connection.
v. Position Probe to a fully Retracted position. Turn the zero screw on the indicator face to
zero meter.
vi. Rotate helipot shaft to the zero degree position and recouple shaft.
vii. Turn POWER ON. Test meter should now read ‘zero’ or almost zero.
viii. Run or crank the unit to the fully extended position.
ix. Move the adjustable resistor slider towards the power connected end until the test meter
reads ten (10) volts.
x. TURN POWER OFF - Disconnect the test meter and connect the leaders to the voltmeter
indicator.
xi. TURN POWER ON - Indicator should now read 100%.
xii. Final adjustment may be necessary. If indicator reads less than full open move the adjustable
resistor slider ahead slightly being careful not to exceed full 100% on the scale. If meter
reads more than zero, when unit is fully closed repeat setting starting with step 6.
xiii. After setting indicator, lock adjustable resistor slider in place.

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5. MAINTENANCE INSTRUCTIONS
5.1 Lubrication
Refer to the lubrication chart.
The drive chains are prelubricated in the manufacturing stage itself and normally we do not recom-
mend any lubrication. Any grease if applied will only attract fly ash accumulation and will result in the
loss of articulation of the chain links. Periodically inspect the chain for any rusting or loss of articula-
tion. If severe damage is noticed degrease the chains and apply a thin coat of oil equivalent to Grade
SAE 30 with a brush so that all the parts will be covered.
5.2 Replacement
A. Thermocouple Replacement
i. Before replacing the thermocouple, the following checks are recommended to insure that
the replacement is necessary:
a. Check all the wiring for breaks and insure that all electrical connections are tight.
b. With the boiler operating run the probe tube forward approximately 300 mm to
place the tip in the higher gas temperature. The temperature read out device should
indicate an increase in temperature if the thermocouple is operating satisfactorily.
c. An alternate method will be to apply heat to the thermocouple and observe the
thermocouple output using a portable potentiometer.
d. If no change in temperature is indicated from the above check, disconnect the
read out device and monitor the thermocouple signal with a suitable test device to
insure that the read out device is operating satisfactorily.
Before proceeding further, disconnect the motor and control power supply.
ii. Remove the housing cover in the out board end and the travelling carriage cover to have
an access to the thermocouple disconnecting plugs. Disconnect the thermocouple extension
wire from the compensating cable.
iii. Pull back the travelling carriage to the extreme out board end and support the lance tube
at two places so that it will not damage to compensating cables. Disconnect the lance
flange from the travelling carriage.
iv. Push the lance inside to some distance so that the thermocouple extension wire is out of
the travelling carriage and remove the lance by tilting and pulling back from the boiler.
v. Loosen the S.S. compression fitting which fixes the thermocouple to the lance and the
thermocouple guide. Pull out the thermocouple from the flange side after attaching a wire
or string to the thermocouple.
vi. Follow the above procedure in reverse for assembling the new thermocouple. Use high
temperature antiseize thread compound in all the threads for easy removal.

B. Potentiometer Replacement:
The variable potentiometer used in the position transmitters assembly is limited mechanically to a
maximum of 10 revolutions of the input drive shaft. Eventhough the maximum possible travel of the
probe utilizes only about 8 revolutions, in order to safeguard the potentiometer at either end of the
10 turn range, proper care should be taken during installation. When replacing the potentiometer,
turn the potentiometer shaft clockwise to the full 10 turn and then turn counter clockwise half turn
before mounting the unit. The position is corresponding to the fully retracted position of the probe.

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RECOMMENDED LIST OF SPARES FOR TEMPERATURE PROBE

SI.No. Description Drg.No./Code No. Qty./Probe

01. Lance Flange Gasket 4-20-791-00389 1


02. STOP Switch Assembly 2-00-073-60093 1
03. Reverse Switch Assembly 2-00-073-60094
04. Chain Traverse 11/2"P 97-366-023 1.5m
05. Connector Link 11/2" 97-366-025 1
06. Offset Link 11/2" 97-377-024 1
07. Cycling Switch Assembly 3-00-073-60124 1
08. Cooling Air Switch Assembly 3-00-073-60123 1
09. Potentiometre Assembly 3-00-073-00110 1
10. Roller Chain3/4"P 97-366-026 0.5m
11. Connector Link3/4"P 97-366-028 1
12. Offset Link3/4"P 97-366-027 1
13. No Slip Pulley 32T 97-366-154 1
14. Bearing 6208 2 RS 55-119-06208 2
15. Gasket (Power Pack) 96-353-052 1
16. Gasket (Travelling carriage) 1
17. Thermocouple Asse mbly Per order 1
18. Airvent 4-20-201-01540 1
19. Gasket 4-20-952-01535 1
20. Bearing 6209 2 RS 55-119-06209 2
21. Bearing 6208 2 RS 55-119-06208 2
22. SPRING 96-353-058 1
23. Motor 0.37 KW 96-272-004 1
24. No slip belt 97-366-153 1
* Only for air cooled Temperature probe

REQUIRED TOOLS FOR TEMPERATURE PROBE


Spanner Allen Key Circlip Pliers

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RECOMMENDED LUBRICATION CHART
SI.No Equipment Recommended Lubricant Method Frequency Frequency Quantity/
Description IOC HP BP of Filling of Change of Observation probe
(Annual)

01. Power pack Servosystem 68 Enklo 68 Bharat Hydrol 68 Reservoir Annual 3 Months
system 68 (See Note:8) 1 Litre

02. Chain Servo Enklo 150 Bharat Hydro 150 By Brush ... ... 1 Litre
See Note: 2

NOTE.-1 Lubricant oil level must be checked and maintained every month.

NOTE.-2 All the Chain and Chain links are prelubricated by a special treatment by which no lubrication is required normally but as and when
14

sign of rust is identified two fold lubrication is recommended First the chain is cleaned and then Trichloroethylene is applied over the surfaces. Servoline
150 Enklo 150 Bharat Hydrol 150 is applied as a second coat by brush.
1216 - 1217 VOL - C1 TAB - 6 -105

ESTIMATED TOTAL QUANTITY OF EACH LUBRICANT


ANNUAL REQUIREMENT PER PROBE

Servosystem 68 (IOC) or Enklo 68 (HP) or Bharat Hydrol 68 (BP) - 0.6kg


Servosystern 150 (IOC) or Enklo 150 (HP) or Bharat Hydrol 150 (BP) - 1.6 litres

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TAB - 7

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INSTRUCTION MANUAL
LRD IIE LONG
RETRACTABLE SOOT BLOWER

PUB.NO.7514

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CONTENTS
GENERAL INFORMATION
LONG RETRACTABLE SOOT BLOWER MODEL LRD-IIE
GENERAL DESCRIPTION (REFER DRG. NO. 0-00-073-60024)
SBV HEAD (DRG. NO. 1-00-073-60003)
INSTZLLATION INSTRUCTION
INSTALLATION INSTRUCTIONS
GENERAL
PIPING
WIRING
ERECTION CHECKS
START UP CHECKS
SOOT BLOWER OPERATION
CHECK LIST
OPERATION
EMERGENCY OPERATION OF SOOT BLOWER
TROUBLE SHOOTING AND MAINTENANCE
PREVENTIVE MAINTENANCE CHECK LIST
INTERNAL INSPECTIONS
EXTERNAL INSPECTION-LONG RETRACT
LUBRICATION
PROCEDURE FOR LANCE AND FEED TUBE REMOVAL
PACKING INSTALLATION
CHAIN TENSION ADJUSTMENT (DRG. NO. 4-20-001-00523)
RECOMMENDED LUBRICATION CHART FOR LRD IIE LONG
RETRACTABLE SOOT BLOWER
OPERATIONAL PROBLEMS AND MAINTENANCE

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RECOMMENDED SPARES FOR LONG RETRACTABLE SOOT
BLOWER(MODEL LRD IIE)
ASPIRATING AND SEALING AIR FOR LONG RETRACTABLE BLOWERS
WITH SINGLE SCRAPER PLATE
SINGLE SCRAPER PLATE AIR SEAL
ASPIRATOR
AIR SEAL
SCRAPER PLATE
FORCED PRESSURE AIR VALVE

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LIST OF DRAWINGS FOR LONG RETRACTABLE
SOOT BLOWER
MODEL T 30 LRD - IIE

SI Drawing No.
No Description
LRSB T 30 M ark LRSB T 30 M ark
II-E II-E Special

1. LRSB M ain Assembly 2-00-073-60080 2-00-073-60084


2. General Arrangement 0-00-073-60024 0-00-073-60025
3. Bill of M aterial 1-00-073-60098 1-00-073-60099
4. M ain Gear Box Assembly (Traverse) 0-00-073-60022
5. M ain Gear Box Assembly(Rotary) 0-00-073-60023
6. Carriage Housing Assembly 0-00-073-60021
7. SBV Head Assembly 1-00-073-600003 _
8. D.A. Head Main Assembly _ 1-00-073-60100
9. Basic Head Assembly _ 1-00-073-60101
10. Adjustable Bearing Assembly 2-00-073-60078
11. Stop Switch Assembly 2-00-073-60079
12. Reverse Switch Assembly 2-00-073-60079
13. W all Blowing limit switch _ 2-00-073-60082
14. Control circuit for combination long _ 2-00-073-60083
Retract and W all blower
15. W iring diagram 3-00-073-60004 3-00-073-60100
16. Chain Tightener(Traverse) 3-00-073-60093
17. Chain Tightener(Rotary) 3-00-073-60094
18. Traverse Chain Assembly 3-00-073-60095
19. Rotary Chain Assembly 3-00-073-60096
20. Jackshaft Bearing Assembly 3-00-073-60097
(Traverse)
21. Jackshaft Bearing Assembly (Rotary) 3-00-073-60098
22. Tools Chart for LRSB 3-00-073-60099
23. Valve Lapping Tool 3-00-073-60094
24. Valve Spring Tool 4-00-073-60157
25. Valve Tamping Tool 4-00-073-60155
26. W rench 4-00-073-60156
27. Valve Spring Tool Assembly 4-00-073-60158
28. Chain Adjustment 4-00-073-00523

FOR DETAILED ERECTION AND START-UP INSTRUCTIONS REFER M ETHODS AND


PROCEDURS FOR INSTALLATION OF SOOT BLOW ERS. PUBLICATION No.7508-78

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GENERAL INFORMATION
The Long Retractable Soot Blowers are designed and manufactured with a view to keep the
boiler operating efficiently. Because of their exclusive dual motor drive, they assure optimum
cleaning of all heating surfaces. BHEL’s Soot Blowers are installed in various power stations
in India and abroad and the sum of the experience gained on many new installations goes
long way in continuous perfection of the equipment. The equipment will function satisfactorily
with a little proper attention to installation, operation and maintenance.
It must be recognized that no amount of written instructions can replace intelligent thinking
and reasoning on the part of the operators, especially when coping with unforeseen operating
conditions. It is the operators’ responsibility to become thoroughly familiar not only with the
equipment but also with all pertinent control equipment.
The instruction contained in this manual is only an outline of the correct procedures for
installation, operation and maintenance. The contents in the manual have been compiled and
checked by experts in the field. Every possible care has been taken to ensure the contents are
accurate. However, it must be understood that the manual is not a contract document.
If you ever have any query about operation, maintenance or related problems, you are welcome
to write to us without obligation.

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SAFETY NOTICE
PROPER SERVICE & REPAIR IS IMPORTANT TO THE SAFE AND RELIABLE
OPERATION OF SOOT BLOWERS. THE SERVICE PROCEDURES DESCRIBED IN THIS
MANUAL INSURING ACCURATE AND PREDICTABLE PRODUCT PERFORMANCE
ARE EFFECTIVE METHODS OF OPERATIONS. THE SPECIAL TOOLS
RECOMMENDED BY BHEL SHOULD BE USED IN SOME OF, THESE SERVICE
OPERATIONS.
IT IS IMPORTANT TO NOTE THAT THIS MANUAL CONTAINS VARIOUS WARNINGS
AND CAUTIONS WHICH SHOULD BE CAREFULLY READ AND FOLLOWED TO
AVOID THE RISK OF PERSONNEL INJURY OR DAMAGE OF THE EQUIPMENT. ANY
ONE WHO USES, A SERVICE PROCEDURE OR TOOL WHICH IS NOT
RECOMMENDED BY BHEL MUST SATISFY HIMSELF THOROUGHLY THAT
NEITHER HIS SAFETY NOR THE EQUIPMENT SAFETY, WILL BE JEOPARDIZED
BY THE SERVICE METHOD HE SELECTS.
EVERY PRECAUTION SHOULD BE TAKEN TO PREVENT INJURY, TO PERSONNEL
DURING -THE PERFORMANCE OF ANY TEST, INSTALLATION OR REMOVAL. BHEL
COULD NOT POSSIBLY EVALUATE ALL CONDITIONS THAT COULD INJURE
PERSONNEL OR EQUIPMENT, BUT DOES OFFER THESE SAFETY PRECAUTIONS
AS AN ASSISTANCE ONLY.
Important instruction for erection, start-up & operation of long retractable soot blowers
DOS
ERECTION
1. CHECK THE BLOWER NUMBERS BEFORE ERECTION.
2. USE ONLY THE LIFTING LUGS FOR HANDLING THE BLOWERS.
3. CHECK THE SQUARENESS AND CONCENTRICITY OF THE WALL BOX.
4. OPERATE THE BLOWER MANUALLY FOR CHECKING THE CLEARANCE
INSIDE THE BOILER.
5. CHECK FOR ACCESSIBILITY FOR THE HAND CRANK FOR MANUAL
OPERATION.
6. COVER THE JUNCTION BOXES AND CABLE OPENING TO PREVENT
WATER ENTRY.
BEFORE START-UP
1. FLUSH THE GEAR BOXES WITH ‘SERVO MESH 28’ AND FILL THEM WITH
THE LUBRICANTS AS RECOMMENDED.
2. CHECK THE DIRECTION OF ROTATION OF BOTH THE MOTORS.
3. CHECK WHETHER ALL COVERS ARE PUT ON THE BLOWER.
4. CHECK THE OPERATION OF THE STOP AND REVERSE LIMIT SWITCHES.
5. OBSERVE ALL SAFETY PRACTICES.
6. CHECK WHETHER THE CORRECT BLOWER IS INSTALLED IN THE
CORRECT LOCATION.
7. CHECK THE LANCE DROOP AT FULLY EXTENDED CONDITION AND
MAKE SURE THAT THERE IS A SURFACE TO SURFACE CLEARANCE OF
100 mm TO 150 mm BETWEEN TOP BOILER TUBES AND LANCE TUBE. IF
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1216 - 1217 VOL - C1 TAB - 7 - 137
THE CLEARANCE IS LESS, PROVIDE SHIELDING AS INDICATED IN
DRAWING.
8. IN THE SIMILAR WAY, CHECK THE SIDE CLEARANCE IN THE
HORIZONTAL PASS.CREDIT SHOULD BE TAKEN FOR PROVISION OF
HORIZONTAL EXPANSION.
START-UP & OPERATION
1. CHECK LUBRICATING OIL LEVELS FREQUENTLY. FOLLOW THE
LUBRICATION SCHEDULE.
2. OBSERVE ALL SAFETY PRACTICES IN USE.
3. ENSURE THAT ALL INTERLOCKS ARE IN OPERATING CONDITION.
4. CHECK WHETHER HAND CRANKS ARE AVAILABLE AT EACH ELEVATION.
5. INSPECT PERIODICALLY FOR THE FOLLOWING
(a) PACKING WEAR (SHOWED BY STEAM LEAKAGE).
(b) RUSTING OF CHAINS.
(c) GASKET LEAKAGE.
(d) CHAIN TENSION.
6. SET THE BLOWING PRESSURE AS PER RECOMMENDED VALUE. ENSURE
THAT THE VALVE GETS COMPLETELY CLOSED AFTER SETTING.
7. ENSURE THE BLOWER LANCES ARE IN HOME POSITION BEFORE AND
AFTER THE SOOT BLOWING CYCLE.
8. WHEN AN ALARM IS SOUNDED DUE TO ELAPSED TIMER, LOW HEADER
PRESSURE, NO BLOWING MEDIUM INTERLOCKS, MAKE SURE THE
LANCE IS WITHDRAWN IMMEDIATELY.
9. IMMEDIATELY ATTEND TO ANY LEAKAGE CAUSED DUE TO:
(a) VALVE LEAKAGE.
(b) FLANGE LEAKAGE.
10. MAKE SURE THE VALVE OPENING LINKAGES ARE IN GOOD WORKING
CONDITION AND THE OPERATION IS SMOOTH.
11. QUICKLY RECTIFY THE TROUBLES WHEN MALFUNCTION IS INDICATED
IN THE PANEL.
12. WHEN THE BLOWERS ARE OPERATED FROM PANEL, KEEP ONE MAN
NEAR TO OBSERVE THE OPERATION.
DONT’S
ERECTION
1. DO NOT MIX UP THE BLOWERS.
2. DO NOT LIFT/HANDLE THE BLOWER WITH ROPE/CHAIN WRAPPED
AROUND.
3. DO NOT USE THE HOUSING AS THE WELDING PLATFORM.
4. DO NOT PLACE HEAVY LOADS ON THE BLOWER.
5. DO NOT PLACE THE BLOWER ON THE PLATFORM WITHOUT PROPER
SUPPORT.
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1216 - 1217 VOL - C1 TAB - 7 - 138
6. DO NOT LEAVE THE LANCE AT EXTENDED POSITION.
START-UP & OPERATION
1. DO NOT OPERATE THE SLOWER WITH WET STEAM.
2. DO NOT OPERATE WITHOUT BLOWING MEDIUM DURING BOILER
OPERATION.
3. DO NOT ATTEMPT MAINTENANCE WORK WHEN POWER AND BLOWING
MEDIUM ARE NOT CUT OFF.
4. DO NOT CRANK THE LANCE MANUALLY WITH STEAM SUPPLY ‘ON’.
5. DO NOT OPERATE THE SOOT BLOWER WITH EXCESSIVE STEAM
LEAKAGE THROUGH PACKING.
6. DO NOT OPERATE THE BLOWER IN QUICK SUCCESSION. MINIMUM ONE
HOUR COOLING PERIOD BEFORE SUBSEQUENT OPERATION IS A MUST
TO AVOID ANY DAMAGE TO MOTOR WINDINGS.
7. DO NOT OVERTIGHTEN THE DRIVE CHAINS (NOISY RUNNING IS O.K.
SILENT RUNNING IS NOT ADVISABLE).
8. DO NOT LEAVE THE LANCE FOR A LONG TIME WITH BLOWING MEDIUM
INSIDE THE BOILER. (IT WILL DAMAGE THE BOILER TUBES, IF KEPT
INSIDE WITH BLOWING MEDIUM).
1. LONG RETRACTABLE SOOT BLOWER MODEL LRD-IIE
1.1 General Description (Refer Drg. No. 0-00-073-60024)
The LRD-IIE model Soot Blower is a boiler cleaning device in which a rotating lance extends
into and retracts from the boiler to make sure that the cleaning medium-steam air-directed
through the nozzles, removes the deposits from tube or wall surfaces.
The lance (item 07) is attached to a carriage housing (item 5) which runs on tracks inside the
blower housing. The carriage and lance are moved by means of a traversing chain (item 15)
operated by a 0.56 kW electric power pack (item 2). Rotary motion is applied to the lance
through the travelling carriage by a second chain (item 16) driven by a separate 0.75 kW
electric power pack (item 3). Control movement is by a stop limit switch and a reverse limit
switch (items 11 and 12).
The unit can be supplied with different traversing and rotating speeds. Standard traversing
speeds are available in various increments from 1.25 to 3.65 m. per minute. Standard rotating
speeds are available in various increments from 4.25 rpm to 7.75 rpm. These speed variations
are accomplished by changing the power pack and jack shaft drive sprockets. Other speeds
are possible for special application by the use of special sprockets.
Normally the blowers will be supplied with 1.65 m/min and 5.92 rpm.
Flow of blowing medium through the retractable soot blower is controlled by the valve (item
4 detailed description is given under the head “ SBV head -) mounted at the rear end of the
blower. The feed pipe item no. 08 is attached to the outlet of this valve head. This feed pipe
passes through packing gland in the traveling carriage and lies inside the lance tube (item 07)
extending to almost the entire length of the blower.
The wheels on the travelling carriage run on tracks welded to the inside of the blower housing
(item 1). Sideways motion is limited by a roller on each side of the carriage which use the
housing sides as guides.

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1216 - 1217 VOL - C1 TAB - 7 - 139
The ends of traversing chain are connected to each end of the carriage (3-00-073-60095). The
rotary chain is continuous (3-00-073-60096). It passes over sprockets on the carriage and
causes rotation through a gear train.
The lance is flanged to the carriage and supported on the boiler end by bearing and yoke plate.
(item 6)
The electric gear box on the right side is for traversing and the electric gear box on the left
side is for rotation when viewed from the rear end of the blower.
Motion is transmitted from the gear boxes to jack shafts on each side of the blower.
Tension on the internal chains are adjusted by adjusting the screws on chain tighteners which
hold the idler sprockets on the outboard end of the unit.
The housing completely covers the blower except the traversing and rotating gear boxes.
The housing is open at the bottom except for tie bars at intervals. A section of the top of the
housing near the rear end of the blower is cut away to, allow access to the travelling carriage.
The access areas have removable cover. A short section of the track at the rear is removable to
permit removing the travelling carriage for major maintenance.
The soot blower valve head item No. 04 is operated by a trip pin (item No. 18 of
(0-00-073-60021) on the top of the travelling carriage which engage a trip cam item No. 27
and through the trip rod item No. 30 linkage and valve lever item No. 25 causes the head
valve to open or close.
The stroke of the head valve is governed by the length of the trip rod. To change the valve
stroke, loosen the jam nuts where it screws into the rod connection and turn the rod.
One end of the rod has a right hand thread, the other end in left hand. When the desired length
is attained tighten the join nuts. The spring on the trip rod should be adjusted to eliminate all
looseness in the assembly.

1.2 SBV Head (Drg. No. 1-00-073-60003)


The Soot Blower Valve head allows the blowing pressure of the blower to beadjusted by
limiting the stroke of the valve. Where it is necessary to reduce the pressure greatly, a fixed
orifice may be installed in the head inlet flange.
The stroke of the head valve is governed by adjustment of the drive screw which contacts the
head valve stem. In the closed position, a minimum clearance of 1mm must be maintained
between adjusting screw and valve stem, to assure tight valve seating.
In general, slag removal will necessitate blowing pressure of 10-16 kg./cm². Soot and fly ash
will need 8-15 kg/cm² and for dust removal, pressure may be as low as 7 kg/cm². In locations
of high gas temperatures, the flow from the lance is determined by cooling requirements of
the lance and may exceed 75 cubic metres per min. of air or 4,500 kg per hour of steam. This
cooling requirement is determined by the furnace gas temperature in which the blower is
operating and the number of square inches of lance surface exposed to these furnace
temperatures. Obviously a 6 metre lance requires a higher flow of blowing medium to keep
it cool than a 3 metre lance. Likewise a 3 metre lance of 76.1 O.D. requires less cooling than
a 3 metre lance of 108 O.D. Always refer to the general arrangement drawing (refer General
Instructions) for a recommended blowing pressure.
CAUTION : DO NOT ADJUST THE VALVE ADJUSTMENT SCREW SO THAT
EVEN IN COMPLETELY RETRACTED POSITION THE VALVE IS KEPT IN OPEN
CONDITION.

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2. INSTZLLATION INSTRUCTION
2. INSTALLATION INSTRUCTIONS
2.1 GENERAL
A wall sleeve and lance scraper plate are provided with each soot blower. The scraper plate
usually just floats on the lance.
In cases where tube and wall movement are identical the sleeve is Welded to both and the
retractable unit is hinged to the sleeve.
The outboard mounting is from auxiliary., steel. via a -hinge hanger arrangement which allows
the boiler end to move with the walls.
For particular information regarding any installation, refer to job drawings. For either type
installation, support members must be installed to avoid interfering with travelling carriage
operation. All supports should be securely made to prevent vibration, which could subject the
supply piping to fatigue strain.
2.2 PIPING
A companion flange, complete with gaskets and fasteners is supplied with each unit. This
flange is to be attached to the blowing medium supply piping. The piping must be free of
strain and have flexibility to allow the blower to move.
2.3 WIRING
Refer to wiring diagrams 3-00-073-60004 for full information on power and control wiring
integral with the blower.
3. ERECTION CHECKS
Ref. Installation Manual Pub. No. 7508-78 for detailed instructions.
(a) The blower should be supported in suck a way that it normally sloped towards the
boiler when the boiler is steaming Please ref. manual Pub. No. 7508-78.
(b) Do not place heavy loading on the blowers. They are not designed for taking, such
heavy loads.
(c) Ensure a minimum surface to surface clearance of 100 mm between boiler tubes
and lance tube at the extended condition of th a lance tube.
(d) Ensure a minimum clearance of 100 mm between the top surface of the boiler tube
and the lowest surface of the lance tubes.
(e) If the clearance is not achieved, the boiler tubes shall be shielded.
(f) Cover all the sliding and electrical parts to prevent accumulation of filth, debris and
water. Make sure all the openings and cover in the junction boxes are, completely
closed during and after field cable connections.
(g) The soot blowers are like precision machines and hence to be handled with care.
Use the lifting lugs and skids to prevent damage to the housing electrical cables and
other parts.
(h) Make sure sufficient number of hand cranks are available at each elevations.
4. START UP CHECKS
For detailed start up checks. (See Pub. No. 7508.)
(a) Check the blower numbers and their location.

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1216 - 1217 VOL - C1 TAB - 7 - 141
(b) Check the chain tension.
(c) Check the position of valve opening cam. (See Pub. NOL. 7508 for details.)
(d) Check all the cable connections.
(e) Check lubrication in the gear box.
(f) Check for free manual movement.
(g) Check the lance/boiler tube clearances.
(h) Check the clearances for manual hand cranking.
(i) Check whether all the blowers are in the initial position.
5. SOOT BLOWER OPERATION
5.1 CHECK LIST

For Long Retractable Soot Blower (LRD-IIE) the following items are to be checked carefully
before initial operation of the blower:
(i) Lubrication level
(a) Travelling carriage.
(b) Rotary Gear box.
(c) Traverse Gear box.
(ii) Chain Tension
(a) Rotary side.
(b) Traverse side.
(iii) Blowing Pressure
(a) Initial setting.
(b) Final setting.
(iv) SBV Head Air Valve (Non-return valve)
Plug is to be removed and the air valve to be installed only in case of forced draft furnace.

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1216 - 1217 VOL - C1 TAB - 7 - 142
(v) Motor Rotation
(a) Rotary drive motor should run-top rotary chain to rear and bottom rotary
chain towards the furnace unless specified.
(vi) Installation of Air Vents
(a) Rotary Gear box.
(b) Traverse Gear box.
(c) Travelling carriage.
(vii) Interference
(a) External interference.
(b) Internal tube (clearance and alignment)
(viii) Pecking Tightness
To be tightened slightly for minimum leakage during operation.
(ix) External Power and Control cable connections. CONTROL PANEL FULLY
OPERATIONAL WITH ALL THE INTERLOCKS IN OPERATING CONDITION.

CAUTION: DO NOT OPERATE THE BLOWER IN QUICK SUCCESSION.


MINIMUM I HOUR COOLING PERIOD BEFORE SUBSEQUENT
OPERATION IS A MUST To AVOID ANY DAMAGE TO MOTOR
WINDINGS.
5.2 OPERATION
i) General
As the start button is pressed the unit begins to extend and rotate. As the nozzles clear the
boiler Wall the carriage strikes the cam, opening the head and blowing commences. At the
fully extended position the travelling carriage strikes the reverse limit switch, (item No. 12 of
main assembly) which closes. momentarily to reverse the unit. As the carriage retracts, it
again strikes the cam closing the - SBV head. The travelling carriage continues its rearward
travel until the cleaning nozzle is retracted into the protection of the wall box at which time
the stop limit switch (item No. 11 in the main assembly) is struck to stop the unit.
(ii) Frequency
The frequency of Soot Blower operation depends on the operating conditions of the boiler
and boiler cleanliness. Some events which may indicate the need for cleaning are, increase in
boiler exit gas temperature, increase in gas pressure loss across the boiler (assuming constant
boiler load) and visual inspection.
It is important when starting up a boiler that the soot blowers be used frequently, and soon
after lighting off. Inefficient combustion in a boiler during start up may result in abnormal
deposits on the tubes. Unless these are removed frequently, furnace explosions or puffs may
result later. It is usually also desirable to use the soot blowers just before taking a boiler out of
service.
Care must be taken to avoid extending the lance into the boiler without flow of blowing
medium, or in subjecting the lance to temperatures in excess of 550°C.
If the lance becomes stalled when partially extended, allow blowing to continue in order to
cool the lance until manual emergency retract Procedure is taken up. When first placing the

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1216 - 1217 VOL - C1 TAB - 7 - 143
blower in service make sure it is in good mechanical condition and that flow of blowing
medium is established properly.
When the soot blowers are not being used, the main blowing medium valve should be closed
tightly.
5.3 EMERGENCY OPERATION OF SOOT BLOWER
(i) To put the soot blower on manual operation.
(a) Switch off power and control supply.
(b) Close the main stop valve of soot blower system to shut off steam/air supply.
(c) Insert the handcrank on the worm shaft and rotate until the blower reaches
starting position.
(ii) Warning
(a) No soot blower should be operated for a second time within one hour interval
to avoid damage to motor windings.
(b) No soot blower should be operated without blowing medium when the boiler
is ‘on‘.
(c) Soot blower should never be manually operated with steam. At the time of
any failure of power or control supply during operation of soot blower, the
blower should be immediately brought to its starting position to avoid any
possible damage to heating surfaces or lance tube. At the end of the traversing
gear box, a slotted stub shaft is provided for hand cranking. After removing
the cap, a hand crank can be engaged to move the lance manually. One hand
crank is normally furnished with each blower.
It is also possible to move the gear box with a portable air motor.
(SPEC: ½” Pneumatic drill suitable adopter for stubbed shaft; SPEED 275
to 300 rpm)
(d) No soot blower lance should be left with blowing medium inside the boiler
for a long time. Failure of bringing the lance to the start position will lead to
damage boiler tubes and the lance.
(e) In compliance with transportation codes, blowers must be shipped with dry
gear boxes. Before operating the blowers fill the power packs with
recommended lubricants.
6. TROUBLE SHOOTING AND MAINTENANCE
Unless soot blowers are properly operated and maintained, there can be lengthy and costly
outages, and need for more expensive replacement of boiler equipments.
Preventive Maintenance Check List
The following is a suggested maintenance schedule. Establish a regular maintenance
programme compatible with conditions at installation.
6.1 At one week intervals
Check for steam leakage in the travelling carriage gland packing. Aslightamount of leakage is
required and permitted. If leakage is excessive change the packing. The entire packing set
should be changed at one time. Follow the instructions for changing the packing. Check for
scoring marks on the feed tube.

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6.2 At one month intervals
(a) Check the travelling carriage and valve for steam leakage. If steam leakage is noticed
tighten the glands and watch the performance during the next Operation.
(b) Check for the steam leak through valve seat. A HOT lance tube (when the line is
charged with steam) is the indication of steam leak through seat, if it is supported by
the hissing noise of steam leakage.
(c) Check the presence of ‘Stop pin‘ on the cam bracket.
(d) Check the angle tracks and chain. If ash building is noticed, clean them.
6.3 At 6 month intervals
(a) Check chain tension of both rotary drive and traversing drive chain. These chains
should be adjusted to ride on the upper angle iron track and on the lower turned
edge of the main housing. The chain should be supported and carried free from
either the driver or the idler end sprockets, or both, for a minimum distance of 750
mm and a maximum distance of 1 metre. Refer Drg. 4-20-001-00523.
(b) Check chain tension of both jack shaft drive chain. The jack shaft drive chains
should be tightened so that normal hand pressure will depress either side of the
chain at the mid point approximately 25 mm.
(c) Chains subjected to caustic or corrosive atmosphere or extremely high temperatures
may require re-lubrication. Lubricate chains as soon as they show signs of rust on
any of the external parts. Replace any chain that is badly rusted or corroded and has
lost articulation. Refer to LUBRICATION SECTION of General Instructions for
recommended lubricants and lubrication procedure. (Pub. No. 7501-79)
(d) Check both “ Stop “ and “ Reverse “ limit switches. The actuating arms should be
tight and secure on the switch pivots. The pivots should be free of paints or oil so
that no hinderance or binding of movement occurs. The actuating arm should be
correctly adjusted so as to pass freely through the slots in the housing and be properly
engaged by the travelling carriage slide roller.
6.4 At one year intervals
(a) Check gaskets at travelling and rotary gear box covers. (Gaskets may have. dried
and shrunk permitting oil seepage). Cap screws on covers should be. tightened.
Replace gaskets if seepage is excessive.
(b) Check oil level in travelling carriage gear boxes. Add recommended lubricant, if
necessary. Refer to LUBRICATION SECTION of General Instructions. (Pub. No.
7501)
(c) Check oil in the reduction gear boxes on the traversing and rotary power packs. Add
recommended lubricant, if necessary. Refer to Lubrication Section of General
Instructions.
(d) Check complete assembly. Tighten loose bolts, nuts and cap screws. Replace missing
cotter pins and springs.
(e) Change motor bearings, if required.
(f) Coat the threaded components with Molyka or antiseize compound so that the rusting
will be prevented.
(g) Check the valve stem assembly for pitting and if pitting is severe replace the stem
with a new one. Apply Molyka on the stem while assembly.

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1216 - 1217 VOL - C1 TAB - 7 - 145
(h) Check the mountings and hanger supports of blower. The hinge pin should be
secured by cotter pins. Lock clamp washers are required to secure mounting shoulder
bolts.
(i) Test, Operate each individual blower
Using the local start button with the blowing medium of the unit under normal operating
conditions, test, operate each individual blower.
Along with the mechanical operation of each blower the blowing pressure also should be
checked by using pressure gauge, in the SBV operating head. The recommended blowing
pressure is shown on the general arrangement drawings Blowing pressure chart.
This manual check is essential to assure that excessive blowing pressures are not incurred
what would cause boiler tube wastage.
6.5 Shut-down checks
In addition to the annual checks as in 6.4 the following checks are to be carried out :
(a) Check whether the boiler tubes have eroded. If thickness is reduced to a very low
value provide of shielding.
(b) Check the gap between the lance tube and the boiler tube. The gap should be kept
min. of 100 mm. For the blowers located in the second pass, the gap between the
lance tube, (at the extended condition) and the coil edge is to be checked. The
minimum distance of 100 mm is to be maintained.
(c) Paint the blowers once in two years.
6.6 Periodical check determined by installation conditions
(a) Check motor starter cabinets.
Cabinets should be kept securely closed and gaskets should be in place to prevent
contamination.
If cabinets have been opened for servicing, carefully blow surfaces free of dust or
foreign material with tight air pressure from a dry, clean air supply. Position
gasketand secure cover.
(b) Packing on the feed tube in the travelling carriage and the valve stem in the SBV
operating head should be tightened. When packing glands are fully down and leakage
is still present, the units should be marked for repacking after the blowing medium is
turned off and the header secured and tagged.
(c) Scraper plates should be inspected for wear as a regular maintenance procedure.
Immediately following start-up, routine examination should begin and should be
scheduled for two month intervals. After completing several bimonthly checks, the
frequency of these inspections may be altered by increasing or decreasing the time
interval between checks (to be determined by the wear pattern)
(d) Internal Inspections
(i) Check to see that nozzles are not worn, cracked or split. Examine inner wall sleeve
edges to make sleeves are not breaking down under heat and thus failing to protect
nozzle heads when they are retracted. See that nozzles are properly retracted for
protection.
(ii) Examine thoroughly all tubes cleaned by these units by rubbing the hands over them
to determine if there are any grooves or flat spots indicating erosion or cutting. Tube

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1216 - 1217 VOL - C1 TAB - 7 - 146
erosion or cutting with Retractable Units is invariably due to excessive blowing
pressure. This pressure should be controlled to avoid the damage. On Long Retract
able Units be careful not to reduce pressure to a point where the volume of
steam.passing through the lance will be insufficient for cooling the lance when
fully extended.
(iii) Space between Water wall tubes where these lances enter is sometimes limited by
boiler construction. Check to see that lances enter the centre of the operating without
striking the boiler tube which could thus be damaged.
(iv) Lances should be straight and true. Straightening procedures as outlined for Rotary
Equipment can be followed.
(e) External Inspection-Long Retract
(i) For general instructions refer Section 5.2-EXTERNAL INSPECTION of Publication
No. 7501.
(ii) Take care when mounting long retractables. Where outboard bearing or boiler end
of the unit is supported and attached to the boiler, the other point should be attached
to structural steel. The boiler will move under heat and load. Thus if more than one
point is attached to steel structures, twisting and bending of the unit will occur with
boiler load changes.
(iii) All units of this type have some sort of the telescoping tube or feed tube running
through a packing gland. Surfaces passing through these glands should be clean,
smooth and free from burrs, cuts of scoring. If they cannot be cleaned, they should
be replaced to prevent excessive packing replacement or damage to mating parts.
(iv) It is sometimes necessary to relocate soot blower units or add additional equipment
to relieve troubles or reduce maintenance. This, as well as a question of change in
design should be deferred until all possible sources of trouble have been eliminated.
6.7 Lubrication
The capacity of the travelling carriage is 1 litre of gear oil. We recommend SERVOMESH 28
for air blowing and 0.6 kg of SERVOGEM HTXX for steam blowing. Where SERVOGEM
HTXX or equivalent is used in the travelling carriage, the grease, after it has been run through
a few operations will find its own level. The volume of this grease should be approximately
half-way on the hollow spindle as a maximum, minimum should be upto the oil level plug.
(if temperatures of blowing steam exceeds 427°C use Almasol 1250).
The reduction gear boxes on the motor power packs have a capacity of 0.75 litre each. Also
the recommended lubricant is SERVOMESH 28. Replace the pipe plugs in the highest opening
in the box with air vents provided loose. Should the chains be subject to caustic or corrosive
atmosphere or extremely high humidity conditions they may require lubrication. Failure to
properly tighten and constantly maintain packing in the travelling carriage of steam blowing
installations will rapidly deplete lubrication on the drive chains.
Chains should be lubricated as soon as they show signs of rust or any of the external
parts. Should chains be badly rusted and corroded in the pins and rollers and the movement
(or articulation) lost, no amount of penetrating oil or lubrication will free those parts which
have seized up. Two-fold lubrication is recommended, when required:
For the first step of the chain lubrication procedure, a light body penetrating fluid should be
applied not only to wash out rust, fly ash, and debris but also to act as a carrier to help the
heavier, lasting lubricant enter the close clearances between pins and rollers.

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We recommend for the first coat Trichloroethylene. Since this penetrating spray must be thin,
it will volatilize and evaporate rather quickly. The application of a heavier more permanent
lube must follow immediately while the penetrating oil is still present, to carry the heavy lube
to the working parts. We recommend for the second coat, Light oil to the grade of SAE-30.
The second coat, should be applied as a thin coat with brush so as to cover and penetrate the
bearing areas. Too much of the lubricant will trap the flyash and will make the chain stiff and
loose the articulation. The Indian Oil grade of SAE-30 will be SERVOLINE-140.
6.8 Procedure for Lance and Feed Tube Removal
The lance tube and feed tube can be removed from the bottom of the blower. For their removal
proceed as follows :
(i) Remove M20 nuts attaching the SBV valve head to the blower and remove the
head.
(ii) Loosen the packings on the travelling carriage.
(iii) Slide the feed tube out of several centimeters and remove two feed pipe retainer
ring halves.
(iv) Disconnect the lance flange from the travelling carriage. Slide the feed tube into the
lance several centimeters. The lance should be supported by a sling through the
housing.
(v) Remove tie bars from the bottom of housing at the head end to allow the lance to be
dropped.
(vi) Lower the end of the lance and feed pipe and pull the lance out of the roller bearing
at the boiler end of the blower and slide it out of the blower housing.
(vii) To reassemble the lance and feed pipe, follow the steps in reverse order.
6.9 Packing Installation
(i) The travelling carriage utilizes a formed packing set. The packing gland nuts should
be drawn up tight enough to effect a seal but not excessive enough to restrict the
travel of the carriage.
(ii) Recommended procedure for Packing Installation
(a) The useful life of packing is dependent on the method of installation. Poor installation
can cause the best packing tofail prematurely. The methods in this procedure, if
followed, will lead to better sealing and longer life.
These packing methods apply both to installing packing in new equipment and
replacing packing in equipment that is in service.
(b) Installation Method (Travelling Carriage Assembly)
Clean out the old packing. Flexible packing hooks are available for removing the
packing.
Inspect the feed pipe for wear or damage. Remove any raised metal that projects
above the normal surface. Do not try to file out depressions or scratches. Raised
metal will tear packing. Any reworking of scratches will only worsen the condition.
Keep the new packing clean during installation. Grit or other hard foreign matter
that is installed with the packing may score the feed pipe causing an early failure
of the packing.
Install all packing rings so that the joints are staggered and kept approximately 90°

17
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1216 - 1217 VOL - C1 TAB - 7 - 148
apart. Spot the joints in clockwise direction to facilitate locating them when removing and
packing.
Install the rings one at a time. Each ring must be set firmly into place with either the gland
or a tamping tool as shown in Drg. 4-20-996-01241. After each ring is installed, the ring must
be compressed with approximately the same force that it will have with the final gland force.
Each ring should be equally compressed when the entire set is installed. If this is not done,
only the last ring will do the sealing and will wear quickly.
Bevelled packing is to be installed with the bevel lip on the shaft pointing toward the pressure.
One end of the tamping tool is angled for bevelled packing. Fit the bevel on the packing to the
bevel on the tool.
Oil or grease may be applied to the outside of braided asbestos packing to help in installing it
in the stuffing box.
Tighten the gland follower, sufficiently tight, after the packing has been installed to insure
final seating of the packing. The nuts should be backed off two or three turns to relieve excessive
pressure. Adjust packing to operating conditions.
Allow packing to leak a small amount, if possible, when starting newly packed equipment.
Tighten the gland slowly as the packing seats.
Do not be afraid to let packing leak a small amount. It is good assurance that packing is not
too tight and the liquid usually has some lubricating qualities.
(c) Installation Method (SBV Head Assembly)
The new packings on the soot blower valve head assembly can be easily assembled removing
the valve from the soot blower.
If packings are installed with the valve mounted on the blower, care should be taken to see the
valve stem assembly does not fall in the soot blower pipe line.
Install the rings one at a time. Each ring must be set firmly into place using the gland bushing.
Follow the Installation procedwe as suggested in 6.7 (b).
For assembling the spring retainer of the valve (item 08 of 1-00-073-60003), use the spring
tool as suggested in the drawing 4-00-073-60158.
When renewing packing, use all new clean packing. Worn packings are dry, highly compressed,
have high friction and may develop scoring. Remember packing is relatively cheap. Labour
and materials necessary to replace worn valve stems are expensive and critical commodities.
The most expensive seal is a seal that fails.
Light gland pressure should be maintained at all times. Too much pressure will cause binding,
scoring of the shaft and force the lubricant out the packing. Too little gland pressure will
allow excessive leakage and washing out of the packing.
When the packing has been compressed to less than 3/4 of its original height, it should be
replaced. The loss of height in packing may indicate a loss of essential lubricant.
6.10 Chain Tension Adjustment (Drg. No. 4-20-001-00523)
The chain must ride on the upper angle iron track and on the lower turned edge of the main
housing. Under no circumstances can the chain be so tight that it will be supported only by the
drive and idler sheave sprockets.
When the chain is being adjusted, the chain should be supported and carried free from either
or both end sprockets, that is either the driver or the idler for a minimum distance of 750 mm
and a maximum of 1000 mm from the sprocket to the track.
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1216 - 1217 VOL - C1 TAB - 7 - 149
The mid-point of the chain from 750to 1000 mm of the driver and 750 to 1000 mm of the
idler must ride on the lower rail.
6.11 Spares
In the enclosed drawings spares that are recommended for stock by the user, are marked by
’S’. While ordering spares the item number and drawing number as found in the Bill of
material and details furnished in the soot blower name plate must be indicated for quick
supply of these items. Section 10 gives the recommended list of standard spares.

7. RECOMMENDED LUBRICATION CHART FOR LRD IIE LONG


RETRACTABLE SOOT BLOWER

Lubrication Filling Observation Method of Qty. per Blower Remarks


Part Description Lubricant
Points frequency frequency application per Filling
Travelling carriage Gervil EP 2 of HPC Fill in the See Note 2
2.1 Annual 3 Months 0.8 litre
(Air blowing) or Servomesh 28 reservoir
Trisona 2 of H PC
Travelling carriage Fill in the See Note 3
2.2 or Almasol 1250 or Annual 3 Months 0.6 Kg.
(Steam Blowing) reservoir
Servogem HTXX
Servoline 140 or See Note I
2.3 Chain - - - -
Enklo 65 of HPC
Power Pack-
Servomesh 28 or Fill in the See Note 2
2.4 Rotary and Annual 3 Months 0.8 litre
Enklo 53 of HPC reservoir
Traverse

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1216 - 1217 VOL - C1 TAB - 7 - 150
8. OPERATIONAL PROBLEMS AND MAINTENANCE
Problem Probable Cause Suggested Remedy
1.Overheating No steam flow/less steam
of the flow
lance tube
(a) Insufficient blowing Increase the blowing
pressure pressure
(b) Valve stem doesn’t move Dismantle and clean the
valve stem
(c) Increase in flue gas Check the boiler
temp. than the designed parameters
value
(d) Absence of valve Assemble the valve
opening screw openingscrew
(e) Slipping of ‘valve open- Adjust the pull rod to
ing lever‘ from ‘Tripping have proper engagement
Lever’
(f) Selection of nozzle size Refer with BHEL (T) and
change the nozzle head
(g) Keeping the lance without Retract the lance immedi-
the blowing medium ately as soon as noticed. If
lance is bent, straighten

(a) Poor quality of packing Use packing


2 Steam recommended
Leakage used for use
through
travelling (b) Further compression Use new packings
carriage impossible as the packings
become solid

(c) Inadequate tightening Tighten the packings:


(Caution : Do not over-
tighten the packings)
(d) Excessive wear of glands Replace the packing with
new glands
(e) Scratch marks, dents or If excessive scratch marks
other surface defect on are noticed, change the feed
the feed pipe pipe

3 Steam (a) Poor quality of packing Use the quality packing


leakage used recommended
through
valve stem (b) Further compression Use new packings
impossible as the pack-
ings become solid
(c) Inadequate tightening Tighten the packings
(Caution : Do not over-
tighten)
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1216 - 1217 VOL - C1 TAB - 7 - 151
Problem Probable Cause Suggested Remedy

4. Chain failure (a) Rusting of the chain and Install new chain
loss of articulation
(b) Assambly of commercial Commercial chains are
chains and links having low breaking load.
These chains will fail fre-
quently. Install spl. quality
chains only
(c) Mounting of wrong motor Check the installation of
on the traverse power correct motor. Check
pack and wrong setting and set the O/L relay as per
of thermal overload relay recommendation
(d) Improper assembly of Assemble connector links
connector links properly
(e) Wearing of chain links Protect chains from ash
and rivets build up or change the
worn out links

5 Motor (a) Bent lance due to over- Remove and straighten the
overload heating lance tube
(b) Wrong setting of O/L Set the O/L relay as per
relay recommendation
(c) Accumulation of ash build Clean the angle tracks
up over angle tracks periodically
(d) Overtightened gland Do not tighten the packing
packings in the travelling too much Profuse leakage
carriage will not harm any parts
(e) Slag build up in wall sleeve Clean the sleeve or adjust
or physical obstruction the SB alignment
(f) Shifting of super heater During shut-down or align
reheater tubes boiler tubes so that a min.
100-150 mm. of gap is
ensured
(g) Housing Damage during Rectify the housing so that
Erection the travelling carriage moves
freely
(h) Valve opening cam in Reposition the cam so that
wrong direction or valve smooth engagement with
opening cam placed at blowing adjustment bar is
wrong position ensured
(i) Earthing of cable at any Find out the cable and
point replace the damaged cable
with a new one
(j) Rusting of terminals Replace the terminals with
which will be indicated new ones
by chattering of contacts
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1216 - 1217 VOL - C1 TAB - 7 - 152
Problem Probable Cause Suggested Remedy

(k) Supply voltage low Ensure the availability of


correct voltage

(l) Gear box jammed or no Service the gear box or fill


lubricant in the recommend lubricant

6 Limit Switch (a) Sticking of contacts due Replace the limit switch
Failure to damage, or due to poor with new ones
quality contact material
or due to underrating of
contacts
(b) Failure of internal parts, Replace the limit switch
springs, locking notches With new ones
etc.
(c) Build up of foreign Replace the broken switch
particles on limit switch arm with a new one
which may result in
breakage of operating
arm
(d) Wrong assembly of limit Reassemble the limit switch
switch so that the overtravel is
restricted to within 50°
(e) Wrong direction of L.S. Correct the directions of
actuation the actuation
7 Valve seat (a) Gland packings over- Loose the gland packings
leakage tightened so that the valve stem
closes properly
(b) Insufficient lapping or Dismantle the valve and
damage to the valve disc lap the valve stem disc with
the use of seat with the hand
lapping tool(as suggested in
7501)
(c) Valve opening setscrew Adjust the valve opening
pressing the valve stem setscrew so that a min.
while the travelling car- gap of 1 mm is maintained
riage is in the home position

(d) Valve stem corrosion. If the corrosion is excessive,


replace the valve stem
(e) Likely small particles This can be avoided by
trapped between seat and tapping the valve through
disc. a lever

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1216 - 1217 VOL - C1 TAB - 7 - 153
S. COMBINATION LONG RETRACT AND WALL BLOWER

Please refer to. the T 30 MK II-E Installation Instructions for general installation and maintenance
information. The specific assembly drawings for this combination retract-wall blower follow this
description of the blower operation. The Assembly drawing and description of the ‘ DA ‘head
furnished on this blower are also included.

Description of Operation (Refer Drg. 0-00-073-60025 and 2-00-073-70083)

Blower operation is initiated by depressing the “ Panel start - or the “ Local start push button. This
creates the circuit to energize the “ CRO - relay and thus starts the rotary motor, causing the lance
to rotate. This “ EXT - relay will be energized through closed centrifugal contacts on the rotary
motor or through ‘ CRO ‘ contact and the limit switch LS1 thus causing the traverse motor starts,
causing the lance to extend from initial position. The circuit will be locked by limit switch LS2 is
tripped.

After a pre-determined travel, limit switch LS3 will be tripped energizing the latching solenoid
valve SV that -controls the DA head, permitting the blowing medium to be admitted to the lance.
The blower will continue to rotate and. extend until the limit switch LS1 is momentarily tripped,
breaking the circuit to “ EXT” and bringing in “ RET “ to cause the lance to retract. The circuit will
be locked by 101 R contacts.

The lance will retract until limit switch LS3 is tripped energizing the timer T and R2 through closed
R1 contacts. This causes the blower to stop, rotate and blow in position until timer ‘T’times out.
When timer ‘T’ times out, 101 R2 will be do-energized. The circuit will be created through closed
R1 and R2 contacts to permit the blower to continue toretract. When timer T times out. energizing
releasing solenoid valve SV to close the DA head and blowing will Stop. Limit switch LS2 will be
stroked causing the blower to atop at its “.REST “ position.

diaphragm Operated ‘ DA’ Head

Assembly Drawing 1-00-073-60100. The ‘DA’ Head is a diaphragm operated valve which controls
the flow of blowing medium to the blower. This head has a poppet type valve, which is stroked by
the interaction of the diaphragm plate, spindle and a lever. The 40 square inch operator requires
air loading pressure in the range of 40 to 80 psi.

When air is supplied to diaphragm it moves up racking lever No. 21 causing adjusting screw No.*
26 to stroke the head poppet valve.

There must be a back lash of at least 1- 16" between adjusting screw No. 26 and poppet valve
stem. Increasing. this backlash reduces blowing pressure.

A number 60 drill blood hole is required in the tubing fitting in stalled in the diaphragm chamber
while the vent port is open to atmosphere.

23
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1216 - 1217 VOL - C1 TAB - 7 - 154
10. RECOMMENDED SPARES FOR LONG RETRACTABLE SOOT BLOWER
(MODEL LRD IIE)

Part MARK
No. Off T 30 M ark II-EII - E
S 1. Ite m As s e mbly Part Drawing
De s cription M ate rial
N o. N o. Drawing No No
Code 1- 6 7- 12 13- 19 Over 20
1. Valve Gland Packing .. 04 2- 00- 073- 60080 - 96/353/365 4 8 12 16
09 1- 00- 073- 60101 -
2. Packing (Travelling Carriage). 41 0 - 0 0 - 0 7 3 - 6 0 0 21 - 97/366/141 4 8 12 16
Chain 2- Pitch One blower requirement length
3. 04 3- 00- 073- 60095 - 97/366/125
.. varies contract to contract
4. Connector Link 2- Pitch .. 01 3 - 0 0 - 0 7 3 - 6 0 0 95 - 97/366/126 2 4 6 8
5. Offset Link 2- Pitch .. 02 3- 00- 073- 60095 - 97/366/127 2 4 6 8
24

Chain 3/4- Pitch One blower requirement length


6. 04 3- 00- 073- 60096 - 97/366/026
.. varies contract to contract
7. Connector Link 3/4" Pitch 01 3 - 0 0 - 0 7 3 - 6 0 0 96 - 97/366/028 2 4 6 8
8. Offset Link 3/4" Pitch 02 3- 00- 073- 60096 - 97/366/027 2 4 6 8
1216 - 1217 VOL - C1 TAB - 7 - 155

9. SBV Head Assembly 04 0- 00- 073- 60024 1- 0 0 - 0 7 3 - 6 0 0 0 3 - 1 2 3 4


10. Oil Seal BSI 18 0 - 0 0 - 0 7 3 - 6 0 0 23 - 96/353/066 4 6 8 12
13 0 - 0 0 - 0 7 3 - 6 0 0 22 -
11. Oil Seal 39 0 - 0 0 - 0 7 3 - 6 0 0 21 - 96/353/310 4 6 8 12
12. Oil Seal 40 0- 00- 073- 60021 - 96/353/311 4 6 8 12

GO TO INDEX
S 1. Ite m As s e mbly Part Drawing Part M ate rial No. Off T 30 MARK
M ark II-EII - E
De s cription
N o. N o. Drawing No No Code
1- 6 7- 12 13- 19 Over 20
GASKET
13 . Spiral Wound Gasket 55 0- 00- 073- 60024
14 . Gasket 05 1- 00- 073- 60003 - 22/021/303 1 2 3 4
11 1- 00- 073- 60101
15. Gasket 12 0 - 0 0 - 0 7 3 - 6 0 0 23 - 22/021/610 1 2 3 4
16 0 - 0 0 - 0 7 3 - 6 0 0 22
16. Motor Gasket 25 0- 00- 073- 60023 -
52 0- 00- 073- 60022 - 22/021/619 1 2 3 4
25

17 . Cover Gasket 15 0 - 0 0 - 0 7 3 - 6 0 0 22 - 22/021/609 1 2 3 4

18 . Gear Box Cover Gasket 17 0 - 0 0 - 0 7 3 - 6 0 0 22 - 22/021/615 1 2 3 4

19. Gasket 4,2- 0 - 0 0 - 0 7 3 - 6 0 0 21 - 22/021/611 1 2 3 4

20. Gasket 43 0- 00- 073- 60021 - 22/021/612 1 2 3 4

21. Bearing Housing Gasket 14 0 - 0 0 - 0 7 3 - 6 0 0 22 - 22/021/613 1 2 3 4


1216 - 1217 VOL - C1 TAB - 7 - 156

22. Motor 1 hp 03 0- 00- 073- 60023 - - 1 1 2 2

23. Motor 3/4 hp 03 0- 00- 073- 60022 - - 1 1 2 2


BEARINIGS
24. Bearing SKF 6210 2RS 06 3- 00- 073- 60097 - 55/119/06210 1 1 2 2

25. Bearing SKF 6206 2RS 06 3- 00- 073- 60098 - 55/119/06206 1 1 2 2

GO TO INDEX
S 1. Ite m As s e mbly Part Drawing Part M ate rial No. Off T 30 M ark II-E
De s cription
N o. N o. Drawing No No Code
1- 6 7- 12 13- 19 Over 20
26. Guide Roll Bearing 05 3- 00- 073- 60093 - 97/366/124 1 1 2 2
05 3- 00- 073- 60094 -
27. Ball Bearing 07 2- 00- 073- 60078 - 96/353/305 1 1 2 2
28. Ball Bearing SKF 6309 10 0 - 0 0 - 0 7 3 - 6 0 0 22 - 55/111/06309 1 1 2 2
03 ' 0 - 0 0 - 0 7 3 - 6 0 0 23
29. Ball Bearing SKF 6204 11 0 - 0 0 - 0 7 3 - 6 0 0 22 - 55/111/06204 1 1 2 2
30. Ball Bearing SKF 6202 12 0 - 0 0 - 0 7 3 - 6 0 0 22 - 55/111/06202 1 1 2 2
31. Ball Bearing SKF 6021 ' C4 33 0 - 0 0 - 0 7 3 - 6 0 0 21 - 55/111/06021 1 1 2 2
32, Ball Bearing SKF 6020 ' C4 34 0 - 0 0 - 0 7 3 - 6 0 0 21 - 55/111/06020 1 1 2 2
33. Ball Bearing SKF 6209 2RS. 35 0 - 0 0 - 0 7 3 - 6 0 0 21 - 55/119/06209 1 1 2 2
Ball Bearing SKF 6205
34. 36 0 - 0 0 - 0 7 3 - 6 0 0 21 - 55/119/06205 1 1 2 2
26

213S.
35. Ball Bearing SKF 6305 . . 37 0- 00- 073- 60021 - 55/111/06305 1 1 2 2
2
36.- Ball Bearing SKF 6005 2RS 38 0 - 0 0 - 0 7 3 - 6 0 0 21 - 55/119/06005 1 1 21

37. Valve Stem Assy. 02 1- 00- 073- 60101 - - 2 4 6 8


02 1- 00- 073- 60003 - -
1216 - 1217 VOL - C1 TAB - 7 - 157

38. Gland 11 0- 00- 073- 60021 4 - 2 0 - 2 0 1, 0 0 2 2 9 - 1 2 3 4


39. Bushing 10 0- 00- 073- 60021 4 - 2 0 - 2 0 1- 0 0 0 7 5 - 1 2 3 4
40. Lance Tube Assy. 07 0- 00- 073- 60024 - - - 1 1
0- 00- 073- 60025
41. Feed Tube Assy. 08 0- 00- 073- 60024 - - - - 1 1
0- 00- 073- 60025
42. Umit Switch 09 2- 00- 073- 60079 - 97/353/900 2 4, 6 8
43. Limit Switch 03 2- 00- 073- 60008 - 97/353/021 2 4 6 8
GO TO INDEX
RECOMMENDED SPARES FOR (SPECIAL) COMBINATION LONG RETRACTABLE
AND WALL BLOWER

Sl. Description Item Assembly Part Part No. off T 30 Mark II – E


no No. Drawing number Drawing number Material code 1-6 7-12 13-19 over 20
01 DA Head valve assembly 01 1-00-073-60100 1-00-073-60101 - 1 1 2 2
02 Gasket 10 1-00-073-60101 - - 1 2 3 4
27

03 Gasket 19 1-00-073-60100 - 22/021/617 1 2 3 4


04 ‘O’ Ring 22 1-00-073-60100 - 96/353/307 1 2 3 4
05 Solenoid valve 42 0-00-073-60025 - 97/366/129 1 1 2 2
06 Exhaust valve 43 0-00-073-60025 - 97/366/130 1 1 2 2
1216 - 1217 VOL - C1 TAB - 7 - 158

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11. ASPIRATING AND SEALING AIR FOR LONG RETRACTABLE
BLOWERS WITH SINGLE SCRAPER PLATE
(Applicable for Pressurised Furnace)
Single Scraper Plate Air Seal
When soot blowers are used on boilers with positive furnace pressures, it is necessary to use
air seal aspirators with the soot blower sleeves. The air seal sleeve is used to prevent escape
of furnace gases from around the lance. The use of an aspirator, while not mandatory with air
seal sleeves, permits removal of a lance with the boiler in operation, without danger of es-
cape of furnace gases. The air seal and aspirator are attached to the soot blower sleeve.
Aspirator
The aspirator consists of a cylindrical annular air chamber, into which high pressure air is
admitted. The lance passes through the central portion of the aspirator. In the cylinder form-
ing the inner wall of the aspirator chamber, there are a series of nozzles drilled on an angle so
that discharge of air through them forms a cone with the base at the aspirator and the apex
several inches forward of the lance tip. When air is admitted to the aspirator the cone of air
prevents flow of furnace gases back through the aspirator and allows removal of the lance or
scraper plate.
Air Seal
The air seal is located directly behind the aspirator. The lance scraper plate forms the rear
wall of this chamber. Low pressure air is introduced into the chamber at a pressure greater
than furnace, and due to small clearance between outside diameter of lance and inside diam-
eter of the scraper plate, an effective seal is formed against furnace pressure.
Scraper Plate
The scraper plate is held in position by a horizontal spring through which the lance passes.
The scraper plate is hardened, and in addition to sealing, will remove deposits on the lance.
When air is admitted to the air seal, an effective seal is made at the lance outside diameter so
furnace gas cannot escape from the boiler.
The lance is positioned so that both nozzles lie behind the air seal in the fully retracted
position, thus the nozzles.are outside the seal, away from furnace gas, which prevents dam-
age from corrosion caused by boiler gases in the lance.
Air at some pressure (see contract drawings) above furnace pressure must be provided at the
inlet to the air seal chamber to effect a proper seal, seal air should be ON whenever the boiler
is in service, with the lance in place. If the lance is removed, the opening must be covered and
the seal air shut off. Aspirating air must be ON when removing or installing the lance or
scraper plate.
Aspirator air pressure is determined by lance size (see contract drawings). Permanent air
connections for aspirating air are not required. Quick disconnect fittings for air hook up are
desirable to speed hook up for maintenance.
The manifold valve must be in “seal” - position when the boiler is in operation. Aspirating air
is supplied (only for short periods) when repairs or replacements are being made with the
boiler in operation.
Before attempting scraper plate maintenance, make sure the aspirating air is ‘ ON’ by placing
the manifold in the ‘aspirate ‘ position. If the seal is to be opened for an extended time, cover
the open end of the aspirator and reduce the aspirator air flow to that necessary to keep the
sleeve cool.
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1216 - 1217 VOL - C1 TAB - 7 - 159
Never allow the aspirator or air seal to be open ended when the boiler is in service without
having aspirating air ‘ ON’.
The air seal should be reassembled by reversing the above procedure. Determine, that the
nozzle head is in the proper position. When the air seal chamber is secured the aspirating air
should be turned OFF and the seal air should be ON.
NOTE: NOZZLES ARE TO BE ON THE OUTBOARD SIDE OF THE SCRAPER
PLATE WHEN THE BLOWER IS FULLY RETRACTED AND IN THE
‘AT REST’ POSITION.
The proper location of these soot blower nozzles should be checked prior to start-up and at
every outage. Should nozzle openings straddle the scraper plate or be on the inboard side, the
seal will be lost and furnace gas will escape which will destroy the lance tip.
Where design dictates that the blower lance be extra, long, so as to extend any blowing nozzle
beyond this air seal (or where half tract blowers are employed) with nozzles on the furnace
side of the scraper plate, while the blower is ‘at rest‘ special provisions are made to seal or
purge furnace gases from the blower.
Forced Pressure Air Valve
For those installations where nozzles are on furnace side of seal air chamber, a forced pres-
sure air valve is located on the soot blower valve. Seal air is supplied to the forced pressure air
valve, by tubing connected to the seal air header. The forced pressure air valve acts as a check
valve to retain high pressure steam in the operating head valve while blowing. After blowing
has been completed, a small spring opens the check to admit seal air to the blower lance and
drive out furnace gases.
Check contract drawings and specifications to determine aspirator and seal air volume re-
quired. This will vary, depending on furnace pressure; there of, specifications on contract
drawings should be checked and followed.
Seal air pressure differential can be checked by extending the retracted soot blower nozzles to
the furnace side of the seal air chamber and through the wall sleeve into the furnace cavity
several inches. The blower is extended as far as possible without actuating the blowing valve
linkage. This will place the blowing nozzles in the furnace area, which will allow furnace
pressure into the lanceand back to the soot blower valve.
CAUTION: SECURE BOTH BLOWING MEDIUM AND ELECTRIC DRIVE
CIRCUITS BEFORE EXTENDING THE LANCE FOR THESE
READINGS TO AVOID INJURY TO PERSONS TAKING THE
READINGS.
The furnace pressure reading can then be obtained on this individual soot blower by installing
a manometer in the 3/8 inch tap on the soot blower valve normally used to measure blowing
pressures.
The seal air pressure should be measured as close as possible to the inlet to the’air seal down-
stream of all air hose fittings and branch line connections. This usually requires a tap in the
last fitting to the air seal manifold valve. The tap can be 1/8 or 1/4 inch pipe thread and a
standard pipe plug used to close the opening when readings have been completed.
With the lance extended and one leg of a “ U “ tube manometer connected to the soot blower
valve tap and the other leg of the manometer to the seal air supply (as described above) the
differential pressure between seal air supply and furnace presssure may be read directly on the
“ U “ tube.

29
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1216 - 1217 VOL - C1 TAB - 7 - 160
At least two readings should be taken under two or more boiler load conditions. Readings are
desirable at nominal or high boiler loads and at relatively low boiler loads. These readings
should be checked against contract data to insure adequate seal air pressure and flow are
available.
Cover
Along with the air seal and aspirator assembly a cover is supplied separately for covering the
furnace opening, in case the seal is to be kept opened for extended period.

30
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31
1216 - 1217 VOL - C1 TAB - 7 - 162
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32
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33
1216 - 1217 VOL - C1 TAB - 7 - 164
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34
1216 - 1217 VOL - C1 TAB - 7 - 165
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35
1216 - 1217 VOL - C1 TAB - 7 - 166
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36
1216 - 1217 VOL - C1 TAB - 7 - 167
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37
1216 - 1217 VOL - C1 TAB - 7 - 168
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38
1216 - 1217 VOL - C1 TAB - 7 - 169
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1216 - 1217 VOL - C1 TAB - 7 - 170
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1216 - 1217 VOL - C1 TAB - 7 - 171
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41
1216 - 1217 VOL - C1 TAB - 7 - 172
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1216 - 1217 VOL - C1 TAB - 7 - 173
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1216 - 1217 VOL - C1 TAB - 7 - 174
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1216 - 1217 VOL - C1 TAB - 7 - 175
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1216 - 1217 VOL - C1 TAB - 7 - 176
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1216 - 1217 VOL - C1 TAB - 7 - 177
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TAB - 8

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METHODS AND PROCEDURES
FOR INSTALLATION
SOOT BLOWERS

Bharat Heavy Electricals Limited


Tiruchirapalli

PUB.NO.7508

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1216 - 1217 VOL - C1 TAB - 8 - 194
CONTENTS
INTRODUCTION
PRECAUTIONS FOR SOOT BLOWER ERECTION
IMPORTANT INSTRUCTIONS ERECTION AND START-UP-LONG
RETRACTABLE SOOT BLOWERS
IMPORTANT INSTRUCTIONS ERECTION AND START -UP-WALL-
DESLAGGER
IMPORTANT INSTRUCTIONS - ERECTION AND START-UP-ROTARY SOOT
BLOWER
LIST OF DRAWINGS
PREPARATION
ERECTION INSTRUCTIONS : LONG RECTRACTABLE SOOT BLOWER
ERECTION INSTRUCTIONS : WALL DESLAGGER
ROTARY SOOT BLOWER
FURNANCE TEMPERATURE PROBE
ERECTION INSTRUCTIONS : HALF RETRACTABLE SOOT BLOWER
ERECTION INSTRUCTIONS : TEH BLOWERS FOR AIR HEATERS
START UP CHECKS
ERECTION INSTRUMENTATIONS : SOOT BLOWER PIPING
START-UP CHECKS - PIPING
THERMAL OVERLOAD RELAY SETTING FOR SOOT BLOWER MOTOR
PROTECTION
CHECK SHEETS

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INTRODUCTION
The following pages contain a recommended procedure for the erection and start-up of all types of
Soot Blowers and Furnace Temperature Probe manufactured by Bharat Heavy Electricals Limited,
Tiruchirapalli. Detailed operation and maintenance instructions are dealt in separate manuals.
The contents are compiled from the expertise available with us. Sufficient care has been taken to
include salient points on erection and commissioning based on the observations made at site as well
as on the feed back available from site.
Every possible care has been taken to ensure- the contents are accurate. Generally the procedure
has been profusely illustrated. It must be recognized that no amount of written instructions can
replace intelligent thinking and reasoning on the part of the erectors, especially when coping with
individual site conditions.
Suggestions for the improvement of the manual would be welcome.
BHARAT HEAVY ELECTRICALS LIMITED
BOILER PLANT - TIRUCHIRAPALLI

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PRECAUTIONS FOR SOOT BLOWER ERECTION
STORE THE SOOT BLOWER COMPONENTS PROPERLY UNDER COVERED ROOF.
BLOWERS SHOULD BE LIFTED USING THE LIFTING LUGS/EYE BOLTS.
EXTRA CARE YOU TAKE DURING ERECTIONWILL ENSURE TROUBLE FREE
OPERATION.
REFER TO ENGINEERING DEPARTMENT FOR ANY DOUBTS/DEVIATIONS IN THE
DRAWINGS.
ENSURE ALL ERECTION WELDING IS DONE BY A CERTI FIED/QUALIFIED WELDER
ONLY.
CHECK THE BLOWER NOS. BEFORE INSTALLATION.
TONNAGE AND QUALITY ERECTION SHOULD GO HAND IN HAND.
INSPECT THE SQUARENESS AND CONCENTRICITY OF WALL BOX WITH RESPECT
TO OPENING.
OPERATE THE SOOT BLOWERS MANUALLY TO CHECK THE INTERFERENCE AFTER
INSTALLATION.
NEVER USE THE SOOT BLOWERS AS WELDING PLATFORM.
IMPORTANT INSTRUCTIONS ERECTION AND START-UP-LONG RETRACTABLE
SOOT BLOWERS
DO’S
ERECTION
1. Look for Blower Numbers on the name plates before erection.
2. Operate the blower manually for checking the clearance inside.
3. Check the squareness and concentricity of the wall box.
4. Check for accessibility for the hand crank for manual operation.
5. Use lifting lugs for lifting.
BEFORE START-UP
1. Flush the power packs with ‘SERVO SYSTEM 68’ and fill them with the lubricants as
recommended.
2. Check the DIRECTION OF ROTATION of both the MOTORS.
3. Check whether all covers are put on the blower.
4. Check the OPERATION of the STOP AND REVERSE LIMIT SWITCHES.
5. Observe all safety practises.
6. Check whether the correct blower is installed in the correct location.
7. For air operated blowers:
(i) Install lubricator and filter near the blower and adjust the lubricator..
(ii) Ensure sufficient compressed air pressure at the inlet.
(iii) Ensure sufficient quantity lubricant in the lubricator periodically.
ADDITIONAL INSTRUCTIONS FOR HALF RETRACTABLE SOOT BLOWERS AND THE
BLOWERS FOR AIR HEATERS.ERECTION
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1. USE CORRECT ELECTRODE FOR WELDING THE LANCE/BLOWING ARM.
2. Check for Alignment of support bearings in the case of half retracts and ‘support channels
in the case of LRNR-IE blowers for Air Heaters.
NOTE: FOR IMPORTANT INSTRUCTIONS ON START-UP, SHUT-DOWN AND
MAINTENANCE REF. INSTRUCTIONS MANUAL PUB. No. 7502 LONG
RETRACTABLE SOOT BLOWER.
DON’TS
ERECTION
1. Do not MIX UP the blowers.
2. Do not use the housing as the welding platform.
3. Do not place HEAVY LOADS on the blower.
4. Do not place the blower on the platform without PROPER SUPPORT.
5. Do not leave the lance at extended position.
BEFORE START-UP
1. Do not operate the blower WITH WET STEAM..
2. Do not operate WITHOUT BLOWING MEDIUM during boiler operation.
3. DO NOT attempt maintenance WORK when POWER AND BLOWING medium are
‘ON’.
4. DO NOT crank the lance manually with STEAM SUPPLY ‘ON’.
5. Do not operate the soot blower with excessive steam leakage through packing.
6. Do not operate the blower in quick succession. MINIMUM ONE HOUR COOLING
PERIOD before subsequent operation is a must to avoid any damage to motor windings.
7. For air operated soot blowers:
DO NOT OPERATE the blower WITHOUT LUBRICATOR AND FILTER.
8. Do not over tighten the drive chains ‘Noisy running is O.K., silent running is NOT Allowed.’
NOTE: LONG RETRACTABLE SOOT BLOWER MODEL LRD-11E SHOULD HAVE
STEAM SUPPLY DURING ‘EMERGENCY’ RETRACT.
IMPORTANT INSTRUCTIONS ERECTION AND START -UP-WALL-DESLAGGER
DO’S
ERECTION
1. Before erecting the blower, check the opening in the boiler wall. It shall be MINIMUM
80 MM through out.
2. Before erecting the wall deslagger, check the wall sleeve for perpendicularity and
concentricity. Check the blower number with reference to location drawing.
3. Check the ACCESSIBILITY FOR HAND CRANK and the switch box assembly.
4. Check whether the WALL DESLAGGER IS PERPENDICULAR after mounting.
5. Check the PROJECTION OF NOZZLE INTO THE WALL.
6. Support the soot blower piping on the BOILER STEEL SUCH AS BUCK STAYS,
FURNACE GUIDES etc.

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7. Check and mark up those units where nozzle is not pointing downwards.
BEFORE START-UP
1. FLUSH the gear boxes thoroughly with ‘SERVOM ESH SP460’ and fill the gear boxes
with the lubricants as recommended.
2. Make sure the DRAIN HOLES in the MOTOR FRAMES point DOWNWARDS and
are open.
3. Check the DIRECTION of rotation of both the MOTORS.
4. Make sure that the stop nuts are in place on the GUIDE RODS.
5. Check whether the COVERS are put on the blower.
6. Check the perpendicularity of the blower when the boiler is working.
NOTE: FOR IMPORTANT INSTRUCIONS ON START- UP, SHUT-DOWN AND
MAINTENANCE.REFER INSTRUCTION MANUAL PUB. No. 7503 WALL
DESLAGGER.
DON’TS
ERECTION
1. DO NOT SUPPORT the blower separately unless otherwise specified.
2. Do not use the blower as a platform/ladder.
3. Do not support the soot blower piping from boiler columns and platforms.
4. Do not place the blowers on the platform without proper support.
BEFORE START-UP
1. DO NOT operate the blower with WET STEAM.
2. Do not set the cam for Micro Limit Switches with ‘POWER’ ON.
3. Do not operate the blowers under low boiler loads without trial operation.
4. Do not hand crank with power and/or steam ‘ON’.
IMPORTANT INSTRUCTIONS - ERECTION AND START-UP-ROTARY SOOT
BLOWER
DO’S
ERECTION
1. Erect the correct Blower in the correct location. (Look for the BLOWER NUMBER on
the reaction plate).
2. Check for the ALIGNMENT of the SUPPORT BEARING of the blowing element.
3. Look for the CORRECT BLOWING ELEMENTS as per the blower number given on
the element.
4. Adjust the nozzle position as per requirement.
BEFORE START-UP
1. FLUSH the power pack thoroughly with ‘SERVO SYSTEM 68’ and fill the same with
the lubricant recommended.
2. Check whether the SWITCH BOX COVER is put on the blower.

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3. Check the DIRECTION OF ROTATION of the motor and blowing element.
4. Check whether the CORRECT BSLOWER is installed IN THE CORRECT
LOCATION.
5. For air operated blowers:
(i) Install the LUBRICATOR AND FILTER near the blower and adjust the
lubricator.
(ii) Ensure SUFFICIENT COMPRESSED AIR PRESSURE at the inlet.
(iii) Ensure SUFFICIENT QUANTITY OF LUBRICANT in the lubricator
periodically.
NOTE: FOR IMPORTANT INSTRUCTIONS ON START-UP, SHUT-DOWN AND
MAINTENANCE.REFER INSTRUCTIONS MANUAL PUB. No. 7504
ROTARY SOOT BLOWER.
DON’TS
ERECTION
1. DO NOT MIX UP the blower.
2. Do not SUPPORT the blower EXTERNALLY unless otherwise specified.
3. Do NOT USE the blower as the PLATFORM.
4. Do not connect the seal air piping rigid. Connect it with a FLEXIBLE hose
5. DO NOT MIX UP the blowing elements.
BEFORE START-UP
1. Do not operate the blower with wet steam.
2. Do not admit steam into the blower when the blowing element is stationary.
3. Do not attend to any repair work with STEAM/POWER ‘ON’.
4. Do not attempt manual rotation when power is ‘ON’.
5. For air operated blowers:
DO NOT OPERATE THE BLOWER WITHOUT THE LUBRICATOR AND FILTER.
LIST OF DRAWINGS
(1) 4-00-073-60085 Long Retractable Soot Blower.
(2) 4-00-073-60086 Wall Deslagger.
(3) 4-00-073-60087 Rotary Soot Blower.
(4) 1-00-073-60059 Seal Air Connection for LRSB.
(5) 3-00-073-60039 Important of Blower Location.
(6) 3-00-073-60040 Typical Alignment of Blowing Element -(Rotary Blower).
(7) 3-00-073-60041 Erection of Wall Blower.
(8) 3-00-073-60044 Location of Filter & Lubricator.
(9) 3-00-073-60045 Erection of LRSB.
(10) 3-00-073-60046 Erection of LRSB.

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1216 - 1217 VOL - C1 TAB - 8 - 200
(11) 3-00-073-60047 Supporting the Wall Deslagger on the Platform.
(12) 3-00-073-60049 Welding of Wall Sleeve.
(13) 3-00-073-60050 Supporting Rotary Soot Blower on the Platform.
(14) 4-00-073-60013 Flange Tightening Sequence.
(15) 4-00-073-60014 Lifting the Rotary Soot Blower.
(16) 4-00-073-60015 Piping Insulation (upto Valve Flange).
(17) 4-00-073-60016 LRSB Support.
(18) 4-00-073-60017 Supporting of Soot Blower Piping (WB-IE).
(19) 4-00-073-60057 Nozzle Adjustment.
(20) 4-00-073-60058 Supporting Long Retractable Soot Blower on the Platform.
(21) 4-00-073-60059 Alignment of Rotary Blower Element.
(22) 4-00-073-60060 Manual Operation of Rotary Blower.
(23) 4-00-073-60062 Alignment of Swivel Tube.
(24) 4-00-073-60063 Position of LRSB.
(25) 4-00-073-60064 Arrangement of the Valve during Steam Blowing.
(26) 4-00-073-60070 Setting of Wall Deslagger Control Cams.
(27) 4-00-073-60071 Draining Arrangement.
(28) 4-00-073-60072 Clearance Space around LRSB.
(29) 4-00-073-60073 Clearance Space around WB-IE.
(30) 4-00-073-60074 Clearance Space around RB-IE.
(31) 4-00-073-60075 Clearance Space around FTP-IE.
(32) 4-00-073-60076 Sealing Air Connection for RB-IE.
(33) 4-00-073-60088 LRD - I - Point Loading - Motors Rear Top Mounted.
(34) 4-00-073-60089 Furnace Temperature Probe - Support Point Loading.
(35) 4-00-073-60090 Seal Air Requirement Chart.
(36) 4-00-073-60091 Aspirating Air Requirements.
LEGEND
LRSB - Long Retractable Soot Blower
WB-IE - Wall Deslagger
RB-IE/RB-IA/RBIM - Rotary Soot Blower
FTP-IE - Furnace Temperature Probe

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LIST OF ERECTION DRAWINGS
BOILER : ....................................................................................
CUSTOMER NO :
....................................................................................

A. LONG RETRACTABLE SOOT BLOWERS:


(i) LRD-I Soot Blower Views.
(ii) LRD-I Long Retrac:
Sleeve Views.
B. WALL DESLAGGER:
(i) WB-IE Soot Blower Views.

C. ROTARY BLOWERS:
(i) Rotary Blower Views.
(ii) Blowing Element.
(iii) Blowing Element.
(iv) Blowing Element.
D. FURNACE TEMPERATURE PROBE:
(i) Furnace Temperature Probe Erection Views.
(ii) Furnace Temperature Probe Sleeve Views.
E. HALF RETRACTABLE SOOT BLOWER:
(i) LRD-1 Half Retract Views.
(ii) LRD-I Half Retract sleeve view
F. TEH BLOWERS FOR AIR HEATERS:
(i) LRNR-I Non Rotating Soot Blower Views.
(ii) LRNR-I Non Rotating Soot Blower Sleeve Views.
G. OTHERS:
(i) Soot Blower Arrangement.
(ii)
(iii)
(iv)
(v)
(vi)

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H. SOOT BLOWER PIPING:
(i)
(ii)
(iii)
(iv)
(v)
(vi)
(vii)
(viii)
(ix)
(x)
1. PREPARATION
(i) Inventory the shipment and immediately report shortages.
(ii) List out the damaged components with reference to the item number in the concerned
assembly drawings and report to Bharat Heavy Electricals Limited, Tiruchirapalli. Refer
the following manuals for the concerned assembly drawings.
(a) Pub. No. 7502: Long Retractable Soot Blowers - LRD-IE.
(b) Pub. No. 7503: Wall Deslagger - WB-IE.
(c) Pub. No. 7504: Rotary Soot Blower - RB-IE.
(d) Pub. No. 7505: Furnace Temperature Probe - FTP-IE.
(e) Pub. No. 7507: Long Retractable Soot Blower Air Operated - LRD-IA,
(f ) Pub. No. 7509: Long Retractable Soot Blower Model LRNR-IE.
(g) Pub. No. 7511: Manual Rotary Soot Blower - Model RB-IM.
(h) Pub. No. 7512: Rotary Soot Blower - Air operated - RB-IA.
(i) Pub. No. 7513: Pneumatic Control Panel - CPP.
(j) Pub. No. 7514: Long Retractable Soot Blower - LRD-11E..
(iii) Check Blower number ,as given in the shipping list/location drawings.
NOTE: ALL BLOWERS ARE NOT IDENTICAL
(iv) Plan for tools, tackles, rigging and handling facilities required for the installation of the
Blowers.
(v) Ensure that all documents like Erection Manuals, Erection Drawings and other relevant
documents are available before commencement of the erection. If not contact BHEL,
Tiruchy for complete documents.
(vi) Programme a sequence of erection in relation to the type of the blowers being erected.
Economics and safety are equally important while erecting the blowers.
(i) Transport
The soot blower assemblies are shipped completely covered with water proof coverings. UNLESS
THE BLOWERS ARE TAKEN FOR IMMEDIATE ERECTION, DO NOT DISTURB THE

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1216 - 1217 VOL - C1 TAB - 8 - 203
COVERINGS. Replace the damaged covers wherever required.
Some assemblies like wall deslaggers; and rotary blowers are shipped with temporary wooden
platforms to prevent parts getting damaged during erection.
THESE ARE NOT TO BE REMOVED TILL THE BLOWERS ARE ERECTED. This will ensure
that the parts are not damaged during handling.
Cover all the electrical items with water proof and dust proof coverings. Nozzle and valve openings
are shipped covered. If any damages are noticed to the covering take necessary actions to rectify it.
(ii) Storage
Normally storage under covered roof is not necessary for soot blowers. When the water proof
covers are removed, wall deslaggers; and rotary blowers must be stored under covered roof if the
interval between soot blower erection and receipt is more than one month.
Always use the lifting lugs or hooks provided to avoid damage to the connected parts Similarly
avoid hitting the assembly against the structures or other boiler components while the soot blowers
are being lifted.
Ensure that the air vent plug in the gear boxes are in place. Avoid leaving open holes in the gear
boxes. IF THE STORAGE PERIOD IS LIKELY TO EXCEED 2 MONTHS FILL THE GEAR
BOXES WITH OIL FOR PROTECTION.
Support the blowers properly during storage. Avoid stacking the blower or placing heavy weights
on the blowers.
(iii) Weight
(a) LongRetract: The weight varies with the travel. For actual values refer 4-00-073-60088.
(b) Wall Deslagger: 150 Kg per blower.
(c) Rotary Soot Blower: 90 Kg per blower.
(d) Furnace Temperature Probe: The weight varies with travel. For actual weight refer
4-00-073-60089.
ERECTION INSTRUCTIONS : LONG RECTRACTABLE SOOT BLOWER
(i ) Supports
The long retractable soot blowers are to be supported at both boiler and rear ends. Unless otherwise
indicated in the drawing, the boiler end shall not be supported in the platforms. (Refer Drg.
4-00-073-60016).
Long retracts are normally slopped towards the boiler when the unit is working. To achieve this,
while erecting due consideration shall be given to the boiler expansion so that at boiler hot conditions
the blower will be slopping towards the boiler. This is to aid condensate drainage into the boiler after
the blowing operation is over. (Refer Drgs. 3-00-073-60045, 3-00-073-60046 & 4-00-073-60063).
The retractable soot blowers are also to be erected inclined considering the horizontal expansion, so
that when the boiler is working the blower will be perpendicular to the wall in the horizontal plane.
The expansion values at different soot blower points are given in the soot blower piping drawings.
NOTE: THIS SLOPE WILL NOT BE APPLICABLE TO HALF RETRACTS AND TUBULAR
AIR HEATER CLEANERS.
(ii) Lifting
While lifting the long retractable soot blower take care to see that no damage is caused to the wiring
and other components by hitting with other structures. Use only the lifting lugs. It is suggested to
have wooden blocks on the sides of the housing so that the slings will not damage the electrical
wiring while lifting. 11
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1216 - 1217 VOL - C1 TAB - 8 - 204
CAUTION: DO NOT REMOVE THE WOODEN GUARDS (Refer Drg. 4-00-073-60058).

(iii) General
(a) Ensure adequate clearance for the lance removal.
(b) Weld the wall boxes with the seal box in such away that the wall box centre line is
perpendicular to the water wall and concentric to the opening (Refer Drgs. 3-00-073-60045
& 3-00-073-60046).
If the lance does not travel perpendicular to the water wall, at the end of forward travel, the gap
between the lance and the nearby tube will be very small. This may lead to erosion and damage to
boiler tubes.
(c) The mounting lugs should be kept horizontal (Refer Drg. 3-00-073-60049) while welding
the wall sleeve assembly.
(d) IMPORTANT: Ensure that the correct blower is erected at the correct location. (Refer
Drg. 3-00-073-60039). The blower number on the name plate should correspond to the
location number in the drawing. All the long retractable blowers are not identical. For example
the size, shape, and position of the nozzle, the material composition of the lance etc., will be
different. Interchanging of the blower will result in damage of the lance tube. Record the
blower Number in 13A Check Sheet Blower Number.
(e) After erecting the long retracts, move the lance forward and backward to check whether
the gap between the lance edge and the boiler tubes is uniform after considering the
allowance kept for horizontal vertical expansion.
(f ) After the electrical connections have been completed, close the terminal box with the
terminal box cover. The cover should be tightened with all screws and gaskets to make
the terminal box weather proof. The incoming cables should be flexible to take up blower
movements and the connections should be properly sealed.
(g) Check whether the scraper plate in the blower assembly rides on the lance loosely. There
should not be any binding.
(h) In the case of pressurised boiler ensure that the nozzle does not lie in the seal chamber
(Refer Drg. 1-00-073-60059).
(i) Do not remove the flange protection plate and the wooden block attached to the
blower near the boiler end, till, the blower is installed. These will protect
the blower parts and the sealing face of the flange.
(j) While erecting the blower ensure that the minimum access is available for maintenanc.Refer
Drg. 4-00-073-60072. It is not possible to alter the soot blower locations, since these are
linked up with the boiler tubes inside. Modification can be only on the structures and
platforms wherever required.
(k) Do not place any heavy objects on the blowers. They are not designed for taking such
heavy loads.
(l) For Air Operated Long Retracts, install the lubricator and filter very close to the blower
(Refer Drg. 3-00-073-60044).
(m) Do not use the blower as the welding platform
IMPORTANT: THE AIR INLET CONNECTIONS SHALL BE KEPT COVERED TILL THE
AIR PIPING IS CONNECTED.

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1216 - 1217 VOL - C1 TAB - 8 - 205
ERECTION INSTRUCTIONS : WALL DESLAGGER
(i) Supports
The wall deslaggers are not to be separately supported unles otherwise specified. The wall deslagger
along with its wall box should be welded with the seal box (Refer Drg. 3-00-073-60041).
(ii) Lifting
Use the eye bolt provided for lifting the wall deslagger see Fig. Since some of the components like
gear housing etc., are made of aluminium, care should be taken while lifting the blowers so that
these parts will not get damaged.
IMPORTANT: Careless handling will break the casting connecting the switch box. DO NOT
REMOVE THE WOODEN PLATFORMS TILL THE BLOWER IS ERECTED. (Refer Drg.
3-00-073-60047)
(iii) General
(a) Ensure adequate clearance for access to the.switch box and hand cranking (Refer Drg.
4-00-073-60073).
(b) IMPORTANT: WELD THE WALL BOX WITH THE SEAL BOX IN SOCH A WAY
THAT THE WALL BOX CENTRE LINE IS PERPENDICULAR TO THE WATER
WALL. IF THIS IS KEPT UP, THE NOZZLE CENTRE LINE WILL
AUTOMATICALLY BE PARALLEL TO THEWATERWALL. WALL BOX SLEEVE
ALSO SHOULD BE CONCENTRIC TO THE SLEEVE BOX OTHERWISE
INTERFERENCE OF THE SWIVEL TUBE WITH THE WATER WALL WILL
RESULT (Refer Drgs. 3-00-073-60041 & 4-00-073-60062).
(c) Check all wall daslaggers for the following :
- Axis of swivel tube is to be perpendicular to plane of boiler wall tubes. NO DEVIA.
TION CAN BE ALLOWED!
- Distance of centre line of clearing nozzle to face the boiler tubes to be cleaned must be 38
mm. (Refer Drg. 4-00-073-60057). This should be set from inside the furnace only. After
this is set by mounting studs and nuts, punch mark the setting on the alignment plate,
taking the wall box flange as the reference. This will be helpful for quick adjustment for
setting, if blowers are dismantled and re-erected for detailed instructions see (iv) “Nozzle
adjustment”.
(d) Ensure the incoming cables to the switch box are flexible and supported externally.
Connections shall be sealed water tight.
(e) The piping for wall blower should always be supported on the buckstays, furnace guides
etc., and never on the supporting structures of platform (Refer Drg. 4-00-073-60017).
(f ) Never allow anybody to stand on the wall deslaggers. This will damage the components
and also whatever adjustment done earlier will be lost. See Fig. 8. NEGLIGENCE OF
THIS WILL RESULT IN TUBE FAILURE.
(g) Ensure the blower with the correct blower number is erected at the correct location.
Some wall deslaggers may have limited angle blowing arrangement.
(h) Do not place any heavy load on the blower especially on the switch box. If this is NOT
FOLLOWED THE SWITCH MOUNT CONNECTOR WILL BREAK.
(i) Before erection, verify whether the nozzle is pointing downwards. If not mark up those
units for adjustments during start up.

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1216 - 1217 VOL - C1 TAB - 8 - 206
(iv) Nozzle adjustment
Nozzle alignment should be made from inside the furnace, referencing the centre line of the nozzle
and wall tube surface, with the nozzle opening parallel to the wall tubes. If the units are set from
outside the boiler through expediency, they should be checked from inside at the first opportunity.
A tool (gauge) for checking the 38 mm nozzle position is supplied in PGMA 20-998 and this could
be used for setting the nozzle position properly thig method of checking from inside is preferred.
Since it is not always possible or practical to check and adjust the location of the wall blower nozzle
from inside the boiler, the following procedure can be used for determining the nozzle location from
outside the boiler, with blower removed. Care must be taken to make sure the proper ‘A’ dimension
is established between the centre line of the nozzle and the face of the tube (usually 38 mm). Refer
to job drawings for the proper dimensions. The swivel tube should be fully extended with the hand
crank and a measurement taken from the centreline of the nozzle to the face to steam chest flange.
This is shown as dimension ‘B’ on Drg. 4-00-073-60057.
A rod of sufficient length to reach through the boiler wall, with 76 mm hook bend at 900 to its
longitudinal axis is used, as shown in the drawing, to establish the location of the inside adjustment
nuts on the mounting studs in relation to the tube. This is shown as dimension ‘C’. (This is to be
carried out before mounting the blower.)
Dimension ‘C’is equal to dimension ‘B’minus dimension ‘A’. The length ‘Co should then be marked
on the rod and the adjusting nuts set to this dimension.Otten the unit is installed, it should be checked
to make sure that it is prependicular with the boiler wall, to ensure cleaning through the full blowing
arc.
The sweep should then be set, if possible, so that the nozzle is pointing down, or in the 6 O’clock
position, when the head opens. This helps to prevent tube cutting from condensate since the
nozzle blows parallel with the tube when the head first opens and condensate is blown of before
the jet sweeps across tubes (Refer Drg. 4-00-073-60057).
5. ROTARY SOOT BLOWER
(i) Supports
The rotary blowers need not be externally supported unless otherwise specified. The rotary blower
along with its wall sleeves should be either welded of fastened as the case may be.
(ii) Lifting
Use the eye bolt provided on the blower for lifting. Since some of the components like reaction
plate, switch box are made of aluminium, care should be taken (Refer Drg. 4-00-073-60014) while
lifting to avoid damage to these parts.
(iii) General
(a) Ensure adequate clearance for the access to switch box and hand cranking (Refer Drg
4-00-073-60074).
(b) Weld the wall boxes with the seal box in such a way that the wall box centre line is
perpendicular to the wall and also concentric. If this is kept up the nozzle centre line will
come parallel to tube lanes (Refer Drg. 3-00-073-60040).
(c) Align the supports for blowing element properly.
If this is not carried out correctly, blowing element may fail or motor may get overloaded
(Refer Drg. 4-00-073-60059)
(d) Unless otherwise indicated, keep the nozzle position of the blowing element downwards
at rest (Refer Drg. 3-00-073-60040). Punch rmarks on element indicate nozzle position
14
GO TO INDEX
1216 - 1217 VOL - C1 TAB - 8 - 207
(See Fig.).
(e) Do not allow the men to stand or place heavy weight on rotary blowers, this will damage
the components and dislocate the alignment.
(f) Ensure the incoming power and control cables are flexible and supported externally The
connections shall be leak tight.
(g) After the installation check the nozzle position for correctness. The nozzle position should
be always as indicated in drg.
(h) Ensure proper element is kept at proper location. The position numbers are usually
punched/stencilled at shop (Refer the concerned erection drg.). Element for high
temperature areas will be stainless steel or chrome plated. ALL ELEMENTS ARE NOT
IDENTICAL.
(i) Install the correct blower in the correct location. There may be variation in the angle of
blowing and the direction of rotation. ALL ROTARY HEADS ARE NOT SAME.
(j) DO NOT REMOVE THE WOODEN PLATFORMS TILL THE BLOWER IS
ERECTED (Refer Drg. 3-00-073-60050).
(k) or detailed instructions on setting the blowing sweep refer to Pub, No. 7504-00, Rotary
Soot Blower, Section 4.
7. FURNANCE TEMPERATURE PROBE
(i) Supports
The Furnace Temperature Probe is to be supported at both boiler and rear ends. Unless otherwise
indicated in the drg., the boiler end shall not be supported in the platforms. While erecting due
consideration shall be given to the boiler expansion so that at hot boiler conditions the probe will be
horizontal and perpendicular to the plane of water wall.
ii) Lifting
Refer to Section 3 (ii) Long Retractable Soot Blower.
iii) General
(a) Before installation, the thermocouple head should be checked.
(b) Weld the wall box on the seal box so that the wall box centre line is perpendicular to the
water wall and concentric to the opening.

Eye hangers are provided for lifiting.Use them.DO not wrap around the wall deslagger for
lifting.

15
GO TO INDEX
1216 - 1217 VOL - C1 TAB - 8 - 208
(c) Ensure adequate clearance for hand cranking and accessibility to other parts (Refer drg.
4-00-0173-00075).
ERECTION INSTRUCTIONS : HALF RETRACTABLE SOOT BLOWER
(i) Supports
Half retract shall be horizontal when the Boiler is steaming. While erecting consider the boiler ex-
pansion for mounting the Half retract. Refer the relevant contract drgs. for expansion values. Blower
should be supported at both boiler and rear ends as indicated for long retractable soot blower.
(ii) Lifting
Refer to Section 3 (ii) of Long Retract.
(iii) Alignment of Supports
The lance extension requires support inside the boiler. This support is to be correctly aligned with
the soot blower opening. If it is not done, motor will get overloaded and/or lance will break
(iv) Alignment of Lance
The lance extension is to be welded with the lance tube in the field. The lance after welding shall be
horizontal. Check the same in different planes using the spirit level.
(v) Welding of Lance
Material of the lance, may be carbon or alloy steel, hence correct electrodes to be used for this
weld. If in doubt, please get the confirmation. This weld is a pressure containing weld and shall be
tested by Radiography.
(vi) Lance Supports
After welding the lance check whether the lance rests on the supports. Extend the lance using the
hand crank and check whether there is any bending.
ERECTION INSTRUCTIONS : TEH BLOWERS FOR AIR HEATERS
(i) Supports
Supports to be provided at (a) Wall box (b) at the rear end. The blower shall be horizontal during
erection.
(ii) General
(a) Alignment of the cross arm to the lance tube to be correctly carried out to prevent binding
of the lance.
(b) The weld between the cross arm and the lance tube is a pressure weld, and this is to be
done by a high pressure welder.
(c) Use the correct electrode for this joint. If in doubt get the confirmation.
(d) Before welding the cross arm, move the cross arm to the full length along the guide
channels. It shall move smoothly.
(e) After welding, extend the lance and check whether the movement is smooth. Take corrective
action if the movement is tight.
(f) Check the level of the support channel before welding the cross arm.
9. START UP:START UP CHECKS
9.1 Long Retractable Soot Blower
(i) Correct blower at correct location.
16
GO TO INDEX
1216 - 1217 VOL - C1 TAB - 8 - 209
(ii) Check the retract slope.
(iii) Check the chain tightness, if loose tighten the adjusting screws provided on the jack shaft
bearing as per the requirement. See Fig. 12 and refer the Instructions Manual Pub. No.
7502: Long Retractable Soot Blower.
(iv) Check whether stop pin is present on the cam bracket.
(v) Check the operation of the limit switches.
vi) Check whether the clutch is engaged.
(vii) Check the direction of rotation of the lance tube (Rotation should be counter-clockwise
viewing from the rear and of the blower.)
(viii) Check whether the proper lubricants are filled up in the gear box and travelling carriage.
(ix) Check the position of the valve opening cam.
(x) Extend the lance manually to check the clearance on the sides. Power shall be off during
manual operation. For manual operation, declutch.
(xi) Close the terminal box with all screws after power and control wiring.
(xii) Check for the smooth operation of the valve opening linkages. Jerky operations must be
corrected.
CAUTION: DO NOT OPERATE MANUALLY WHILE BLOWING MEDIUM IS ON.
9.2 Wall Deslaggers
(i) Extend the swivel tube manually to see whether it interferes with the water wall tube.
(ii) Check the nozzle at the extended portion. The nozzle shall be pointing down at the start of
the cycle.
(iii) Check operation of the micro limit switches and set the same by operating the manual
crank - For setting Limit Switches Refer Detailed Drg. 4-00-073-60070.
(iv) Check whether the cable to rotary gear box is cleared while the gear box is advancing.
(v) Check the direction of rotation of swivel tube. Usually it will be clockwise viewing from
the rear end of the blower.
(vi) Check whether the switch box is tightly closed.
(vii) Check whether the lubricants are filled in the gear boxes.
(viii) Check whether the limit switch operating cam on the swivel tube is correctly positioned.
(ix) Check whether the nuts on the guide rods are present. If not, do not operate till they are
placed.
CAUTION: DO NOT OPERATE MANUALLY WHILE POWER IS ON.

17
GO TO INDEX
1216 - 1217 VOL - C1 TAB - 8 - 210
9.3 Rotary Soot Blower
(i) Disengage the coupling and check the rotation of the blowing element with a spanner
(Refer Drg. 4-00-073-60060).
(ii) Check the starting position of the blowing, the direction, angle of blowing, and the nozzle
position.
(iii) Check the operation of the valve opening and closing mechanism.
(iv) Check whether the switch box cover is closed tightly.
(v) Check whether the correct blowing element is erected at the correct location.
(vi) Check whether the proper lubricants are filled in the gear box.

9.4 Half Retractable Soot Blower


(i) Check the points (i) to (xi) given under 9.1.
(ii) Operate the blower, during the hot boiler condition and check whether motors draw more
current than the rated.
CAUTION: DO NOT OPERATE THE BLOWER IN DECLUTCHED CONDITION WITH
STEAM.
9.5 T.E.H. Blowers or Air Heaters
(i) Check the points (i) to (xi) given under Section 9.1.,
(ii) Operate the blower during the hot boiler condition and check whether the motor draws
more current than the rated.
CAUTION: DO NOT OPERATE THE BLOWER IN DECLUTCHED CONDITION WITH
STEAM.
9.6 Air Operated Long Retractable and Rotary Soot Blowers
(i) Check whether the lubricator and filter are in the compressed air line and fill the lubricator
and adjust the same for 5 drops/mt.
(ii) Check the pressure of the compressed air. It should be min. of 80 PSIG at the Soot
Blower.
(iii) Check for air leakages in the power and control air lines.
9.7 Furnace Temperature Probe
(i) Check the chain tightness and presence of rusting.
(ii) Check the operation of the Limit Switch.
(iii) Check whether the proper lubricant is filled in the gear box.
(iv) Check all thermocouple junction for tight terminal connections.
(v) Check for pressure tightness of the air hose if the probe is provided with air cooling
arrangement and the required air pressure.

18
GO TO INDEX
1216 - 1217 VOL - C1 TAB - 8 - 211
(vi) Use the Rheostat for adjusting position indicator.
(vii) Check whether the temperature Indicating/recording circuit is provided with temp high
retract interlock.
9.8 General
(i) All the gear box should be checked for lubricant at required quantity and topped up if
necessary. All the air vents should be in place
(ii) Check all the valve operating linkages, the valve opening setscrew should project suffi-
ciently to open the valve.
(iii) Check the IR value of the motors. Normally all motors will be alright, since all are weather
proof.
(iv) If boiler is not working all the blower can be electrically operated with local push button
stations without steam. Check the correct directions of rotation/operation.
(v) When the soot blower is in operation observe the smoothness of valve opening and
closing, the operation should be smooth without any jerks. Check whether retract lance is
rotating while advancing.
(vi) Check the electrical overload relays and thermal relays for proper matching with the soot
blower motor particulars.
(vii) If orifice is indicated in the valve head, check whether this is installed.
(viii) Check before operating on steam whether the valve opening screws will open the valve.
(ix) If the furnace is pressurized check whether seal and aspirating air have been connected
properly and required pressure is available.
(x) Check whether lubricator and filter are provided in air line for AIR OPERATED SOOT
BLOWER, and proper lubricant with sufficient quantity is available.
(xi) Follow the commissioning procedures for commissioning the soot blowers as indicated in
Pub. No. 7501 Soot Blower: General Instructions.
(xii) Set the blowing pressures on all blowers as per the chart given in General Instruction
7501 (or concerned contract drg.)
Follow the procedure as indicated in General Instruction 7501 and record in “13-B Check
Sheet: Blowing Pressure”.
NOTE: IN CASE THE CONTROL PANEL AS WELL AS MOTOR CONTROL CENTRE
ARE NOT READY, PRE-COMMISSIONING OF SOOT BLOWERS CAN BE
CARRIED OUT USING A TEST CONTROL BOX. FOR THE DETAILED
INFORMATION ON THIS, CONTACT BHEL, TIRUCHY.
ERECTION INSTRUMENTATIONS : SOOT BLOWER PIPING
10.1 SOOT BLOWER PIPING
(i) Routing
Routing of the pipe line shown in the concerned contract drawing is suggestive. Carry out the final
routing suitably considering the following points.
(a) Easy accessibility for operation and maintenance of valves and fittings.
(b) Adequate head room wherever the tubes are crossing walkways and platforms.
(c) Enough clearance for pipe from structural members.

19
GO TO INDEX
1216 - 1217 VOL - C1 TAB - 8 - 212
(d) Adequate flexibility to absorb differential expansion.
(e) Clearance from approach to doors and other apertures.
(ii) Drain
Erect the piping with adequate slope (5to 15°) so that the drain canflow away promptly. Avoid
horizontal pipe arrangement. If unavoidable provide suitable drain piping to the vertical header.
iii) Support the pipe line with eye hooks (eye hangers) as indicated in the concerned contract
drawing.
iv) Support the pipe line to wall deslaggers to boiler steel such as buck stays, furnace guides
instead of supporting on structural steel.
(v) Provide the expansion loops as indicated in the concerned contract drawing.
(vi) Insulate the soot blower piping upto the valve head mating flange as shown in Drg. No.
4-00-073-60015.
vii) Tubes, angles, channels are issued in running meters and to be cut for the required lengths
at site.
viii) Prepare the edge preparations for the tubes as per standard edge preparation.
(ix) Carry out the welding with the certified welders.
(x) Do not,support the piping on the soot blower valve.
(xi) Support,the safety valve exhaust pipe as indicated in the concerned contract drawing.
xii) Use pipe anchors and pipe guides as suggested in the contract drawing.
xiii) Follow the sequence of tightening of the soot blower companion flange and the valve
head as indicated in Drg. No. 4-00-073-60013.
10.2 SEAL AIR PIPING - ERECTION
Seal air piping is provided to prevent the flue gases escaping through the wall openings in the case of
pressurised furnace. Normally seal air is taken from forced draft fan outlet.
(i) Avoid sharp bends in the air line.
(ii) Avoid rigid connections to the blower and use flexible rubber hoses in between the air line
header and the blower to prevent the boiler expansion stressing the seal air piping.
(iii) See that all the connections are air tight.
(iv) Connect the seal air line to the points indicated in the respective soot blowers. These will
normally be indicated in the contract drawings (Refer Drg. 1-00-073-60059
4-00-073-60076).
10.3 ASPIRATING AIR PIPING-ERECTION
Aspirating air is provided in the pressurised wall boxes of long retracts and furnace probes to
facililate their removal while the boiler is working. This line taken from the plant compressed air
system, and will be having a pressure of minimum 5 Kg/cm2 g.
(i) Avoid sharp bends.
(ii) All joints shall be pressure tight.
(iii) Provide an orifice to reduce to the required pressure.
(iv) Isolating valves are to be provided for each air connection to the blowers.

20
GO TO INDEX
1216 - 1217 VOL - C1 TAB - 8 - 213
11. START-UP CHECKS - PIPING
(i) Soot Blower Piping (Steam)
(a) Check expansion loops for thermal expansion provision.
(b) Check for slope drainage.
(c) Condensate drainage shall be from trap to atmospheric pressure.
(d) Condensate drainage through permanent leak off valve shall be to blowdown tank.
(e) Check whether the piping is supported with sufficient pipe hangers.
(f ) Check whether the piping at the wall blower locations are supported at the buck stays or
furnace guides etc.
(g) Carry out the hydraulic test at the pressure of 70 Kg/cm2 g in the piping. While doing so
check whether all the flanges are blanked with blank flange supplied in P.G. 21. The soot
blower valve heads are not to be included. DO NOT PRESSURIZE THE VALVE MORE
THAN THE T.C. VALVE
(h) Blow off the piping with steam as suggested below:
The practice of steam blowing the main line (main vertical header) through the drain valve will result
in incomplete cleaning of the branch line, which may lead to valve failure and Scoring of the finely
ground feed tube and swivel tube.
TO AVOID THIS, BLOW THE INDIVIDUAL LINES TO SOOT BLOWER SEPARATELY.

During steam blowing protect the valve internals. Use a flat sheet to cover the valve flange and tie it
with the flange, as shown in Drg. 4-00-073-60064. The pressure of steam blowing should be
minimum 15 Kg/cm2g. At this time keep the control valve, full open and drain valve closed. Repeat
the blow 3 or 4 times for each branch.
(i) Check and record the warming up time required for the piping. Identify the branches
where water hammer is present. Additional drain connections may be required in these
lines, since the slope is not sufficient for draining the condensate (Refer Drg.
4-00-073-60071).
(j) Check the function of the control valve. Control valve shall be in operation before
commencing the soot blower operation. Check control valve function when the soot
blower is in operation. Safety valves will not open if the control valves are acting fast
enough.
(k) Check for leakages and binding in the aspirating and seal air lines.
(l) Check the differential pressure of seal air when the seal air is on. This check will ensure
adequate seal air pressure for each opening (Refer Drg. 1-00-073-60059). Check whether
the measured pressure is correct as given in 4-00-073-60090 (for Retracts and Probe).
(m) Check the function of the aspirating arrangement for proper working.
(n) Check pressurized furnace seal air systems.
(o) Check the aspirating air pressure on all blowers and check for correctness as given in
4-00-073-60091 (for Retracts and Probe).

21
GO TO INDEX
1216 - 1217 VOL - C1 TAB - 8 - 214
(ii) Pressurized Furnace Seal Air Systems
A. Retracts
(a) Check all nozzles to see that all parts of nozzles are within two scraper plates that form the
seal air void in the case of two scraper plate design. This should be checked and inspected
before boiler operation.
(b) Follow the instructions of extending blowing nozzles into furnace and reading seal air
pressure differential against dynamic seal air supply pressure where it enters the manifold
valve on the air seal aspirator assembly.
(c) Where nozzles are extended beyond seal air void, as on short stroked or extended lances
on half retracts and air preheater cleaners, see that the forced pressure air valves are
properly installed and properly supplied with seal air.
(d) Make certain all manifold valves are correctly positioned to deliver seal air when boiler is
under load and being fired.
B. Wall Deslagger
(a) Follow instructions on extending blowing nozzles into furnace and reading sealair pressure
differential against dynamic seal air supply pressure where it entres wall box adoptor.
(b) Check all wall deslaggers to see they are properly equipped with forced pressure air
valves are properly tubed and supplied with seal air so as to purge blower internals.
(c) Make certain that all 3 way supply valves on the seal air aspirator combined supply line
are correctly positioned to supply seal air when the boiler is fired.

22
GO TO INDEX
1216 - 1217 VOL - C1 TAB - 8 - 215
23
GO TO INDEX
1216 - 1217 VOL - C1 TAB - 8 - 216
13-A CHECK SHEET: BLOWER NUMBER

Type of Soot Type of Soot


S 1. N o. Blowe r No. As in Contractdrg. As e re cte d S 1.N o. Blowe r No. As in Contract drg. As e re cte d
Blowe r Blowe r
drg
24
1216 - 1217 VOL - C1 TAB - 8 - 217

GO TO INDEX
13-A CHECK SHEET: BLOWER NUMBER

Type of Soot Type of Soot


S 1. N o. Blowe r No. As in Contractddrg
rg. As e re cte d S 1.N o. Blowe r No. As in Contract drg. As e re cte d
Blowe r Blowe r
25
1216 - 1217 VOL - C1 TAB - 8 - 218

GO TO INDEX
13-A CHECK SHEET: BLOWER NUMBER

Type of Soot Type of Soot


S 1. N o. Blowe r No. As in Contractddrg
rg. As e re cte d S 1.N o. Blowe r No. As in Contract drg. As e re cte d
Blowe r Blowe r
26
1216 - 1217 VOL - C1 TAB - 8 - 219

GO TO INDEX
13-A CHECK SHEET: BLOWER NUMBER

Type of Soot Type of Soot


S 1. N o. Blowe r No. As in Contractddrg
rg. As e re cte d S 1.N o. Blowe r No. As in Contract drg. As e re cte d
Blowe r Blowe r
27
1216 - 1217 VOL - C1 TAB - 8 - 220

GO TO INDEX
13-B CHECK SHEET: BLOWING PRESSURE

TIME FOR WARM UP : IN MINUTES

Blowing pre s s ure Blowing pre s s ure


Type of Soot As in Contract As me as ure d Type of Soot As in Contract drg.in As me as ure d in
S 1.N o. Blowe rNo. S 1.N o. Blowe rNo.
Blowe r - drg.in kg/cm2(g) in kg/cm2(g) Blowe r kg/cm2(g) kg/cm2((g)
g)
28
1216 - 1217 VOL - C1 TAB - 8 - 221

GO TO INDEX
13-B CHECK SHEET: BLOWING PRESSURE

TIME FOR WARM UP : IN MINUTES

Blowing pre s s ure Blowing pre s s ure


Type of Soot As in Contract As me as ure d Type of Soot As in Contract drg.in As me as ure d in
S 1.N o. Blowe rNo. S 1.N o. Blowe rNo.
Blowe r - drg.in kg/cm2(g) in kg/cm2(g) Blowe r kg/cm2(g) kg/cm 2(g(g)
)
29
1216 - 1217 VOL - C1 TAB - 8 - 222

GO TO INDEX
13-B CHECK SHEET: BLOWING PRESSURE

TIME FOR WARM UP : IN MINUTES

Blowing pre s s ure Blowing pre s s ure


Type of Soot As in Contract As me as ure d Type of Soot As in Contract drg.in As me as ure d in
S 1.N o. Blowe rNo. S 1.N o. Blowe rNo. 2
Blowe r - drg.in kg/cm2(g) in kg/cm2(g) Blowe r kg/cm2(g) kg/cm ((g)
g)
30
1216 - 1217 VOL - C1 TAB - 8 - 223

GO TO INDEX
13-B CHECK SHEET: BLOWING PRESSURE

TIME FOR WARM UP : IN MINUTES

Blowing pre s s ure Blowing pre s s ure


Type of Soot As in Contract As me as ure d Type of Soot As in Contract drg.in As me as ure d in
S 1.N o. Blowe rNo. S 1.N o. Blowe rNo.
Blowe r - drg.in kg/cm2(g) in kg/cm2(g) Blowe r kg/cm2(g) kg/cm2((g)
g)
31
1216 - 1217 VOL - C1 TAB - 8 - 224

GO TO INDEX
13-C CHECK SHEET: SEAL AIR PRESSURE
FOR PRESSURISED BOILERS

Type of s oot
Type of Soot Se al Air Pre s s ure
S 1.N o. Blowe r Blowe r No. Se al Air Pre s s ure Sl. No. Blowe r No.
Blowe r

As me as ure d As me as ure d in
As in. Contract
in mm of As in Contract drg. in mm of Wate r
drg.in mm of
Wate r Column mm of Wate r Column Column
Wate r Column
32
1216 - 1217 VOL - C1 TAB - 8 - 225

GO TO INDEX
13-C CHECK SHEET: SEAL AIR PRESSURE
FOR PRESSURISED BOILERS

Type of s oot
Type of Soot Se al Air Pre s s ure
S 1.N o. Blowe r Blowe r No. Se al Air Pre s s ure Sl. No. Blowe r No.
Blowe r

As me as ure d As me as ure d in
As in. Contract
in mm of As in Contract drg. in mm of Wate r
drg.in mm of
Wate r Column mm of Wate r Column Column
Wate r Column
33
1216 - 1217 VOL - C1 TAB - 8 - 226

GO TO INDEX
13-C CHECK SHEET: SEAL AIR PRESSURE
FOR PRESSURISED BOILERS

Type of s oot
Type of Soot Se al Air Pre s s ure
S 1.N o. Blowe r Blowe r No. Se al Air Pre s s ure Sl. No. Blowe r No.
Blowe r

As me as ure d As me as ure d in
As in. Contract
in mm of As in Contract drg. in mm of Wate r
drg.in mm of
Wate r Column mm of Wate r Column Column
Wate r Column
34
1216 - 1217 VOL - C1 TAB - 8 - 227

GO TO INDEX
13-C CHECK SHEET: SEAL AIR PRESSURE
FOR PRESSURISED BOILERS

Type of s oot
Type of Soot Se al Air Pre s s ure
S 1.N o. Blowe r Blowe r No. Se al Air Pre s s ure Sl. No. Blowe r No.
Blowe r

As me as ure d As me as ure d in
As in. Contract
in mm of As in Contract drg. in mm of Wate r
drg.in mm of
Wate r Column mm of Wate r Column Column
Wate r Column
35
1216 - 1217 VOL - C1 TAB - 8 - 228

GO TO INDEX
13-D CHECK SHEET:
WALL DESLAGGER NOZZEL SETTING

S 1.N o. Blowe r.No. Dime ns ions in mm SI. No. Blowe r.No Dime ns ions in mm
'A' 'B' 'C' 'B-C' 'A' 'B' 'C' 'B-C'
36
1216 - 1217 VOL - C1 TAB - 8 - 229

GO TO INDEX
13-D CHECK SHEET:
WALL DESLAGGER NOZZEL SETTING

S 1.N o. Blowe r.No. Dime ns ions in mm SI. No. Blowe r.No Dime ns ions in mm
'A' 'B' 'C' 'B-C' 'A' 'B' 'C' 'B-C'
37
1216 - 1217 VOL - C1 TAB - 8 - 230

GO TO INDEX
13-D CHECK SHEET:
WALL DESLAGGER NOZZEL SETTING

S 1.N o. Blowe r.N o. D ime ns ions in mm SI. N o. Blowe r.N o D ime ns ions in mm
'A' 'B' 'C' 'B-C' 'A' 'B' 'C' 'B-C'
38
1216 - 1217 VOL - C1 TAB - 8 - 231

GO TO INDEX
13-D CHECK SHEET: WALL DESLAGGER NOZZEL SETTING

S 1.N o. Blowe r.No. D ime ns ions in mm SI. No. Blowe r.No D ime ns ions in mm
'A' 'B' 'C' 'B-C' 'A' 'B' 'C' 'B-C'
39
1216 - 1217 VOL - C1 TAB - 8 - 232

GO TO INDEX
GO TO INDEX
40
1216 - 1217 VOL - C1 TAB - 8 - 233
GO TO INDEX
41
1216 - 1217 VOL - C1 TAB - 8 - 234
GO TO INDEX
42
1216 - 1217 VOL - C1 TAB - 8 - 235
GO TO INDEX
43
1216 - 1217 VOL - C1 TAB - 8 - 236
GO TO INDEX
44
1216 - 1217 VOL - C1 TAB - 8 - 237
GO TO INDEX
45
1216 - 1217 VOL - C1 TAB - 8 - 238
GO TO INDEX
46
1216 - 1217 VOL - C1 TAB - 8 - 239
GO TO INDEX
47
1216 - 1217 VOL - C1 TAB - 8 - 240
GO TO INDEX
48
1216 - 1217 VOL - C1 TAB - 8 - 241
GO TO INDEX
49
1216 - 1217 VOL - C1 TAB - 8 - 242
GO TO INDEX
50
1216 - 1217 VOL - C1 TAB - 8 - 243
51
GO TO INDEX
1216 - 1217 VOL - C1 TAB - 8 - 244
52
GO TO INDEX
1216 - 1217 VOL - C1 TAB - 8 - 245
GO TO INDEX
53
1216 - 1217 VOL - C1 TAB - 8 - 246
GO TO INDEX
54
1216 - 1217 VOL - C1 TAB - 8 - 247
55
GO TO INDEX
1216 - 1217 VOL - C1 TAB - 8 - 248
GO TO INDEX
56
1216 - 1217 VOL - C1 TAB - 8 - 249
57
GO TO INDEX
1216 - 1217 VOL - C1 TAB - 8 - 250
GO TO INDEX
58
1216 - 1217 VOL - C1 TAB - 8 - 251
GO TO INDEX
59
1216 - 1217 VOL - C1 TAB - 8 - 252
GO TO INDEX
60
1216 - 1217 VOL - C1 TAB - 8 - 253
61
GO TO INDEX
1216 - 1217 VOL - C1 TAB - 8 - 254
62
GO TO INDEX
1216 - 1217 VOL - C1 TAB - 8 - 255
63
GO TO INDEX
1216 - 1217 VOL - C1 TAB - 8 - 256
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64
1216 - 1217 VOL - C1 TAB - 8 - 257
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65
1216 - 1217 VOL - C1 TAB - 8 - 258
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66
1216 - 1217 VOL - C1 TAB - 8 - 259
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67
1216 - 1217 VOL - C1 TAB - 8 - 260
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68
1216 - 1217 VOL - C1 TAB - 8 - 261
69
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1216 - 1217 VOL - C1 TAB - 8 - 262
70
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1216 - 1217 VOL - C1 TAB - 8 - 263
71
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1216 - 1217 VOL - C1 TAB - 8 - 264
72
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1216 - 1217 VOL - C1 TAB - 8 - 265
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73
1216 - 1217 VOL - C1 TAB - 8 - 266
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74
1216 - 1217 VOL - C1 TAB - 8 - 267
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75
1216 - 1217 VOL - C1 TAB - 8 - 268
TAB - 9

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1216 - 1217 VOL - C1 TAB - 9 - 269