Instruction Manual Diamond Model IR-3Z Furnace Wall Soot Blower

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•- ondPower

'" Machine [HubeiJ CO. Inc.

a Diamond Power Inlemolionol, Inc. campony

Instruction Manual

DIAMOND MODEL IR-3Z FURNACE WALL SOOTBLOWER

IM-15035 (DPMH-EN) 05~08

IMPORTANT NOTICES

Cautions, Warnings and Safety Information

1. This manual has been prepared for use by those responsible for the operation and maintenance of the equipment. Please read the entire manual before installing, operating or maintaining the equipment. NOTE: Failure to adhere to the procedures and methods in this manual or failure to use Diamond Power parts or procedures may void any stated or implied warranty.

2. This manual contains numerous warning and cautionary notes. Carefully read and comply with all warnings and cautions to minimize the risk of personal injury or damage to the unit. In this manual, "WARNING" constitutes a possible personal injury situation and "CAUTION" constitutes possible equipment damage that may render it unsafe or may void the warranty. These warnings and cautions are not exhaustive, so adherence to general safety practices should always accompany operation and maintenance of the unit.

3. The contents of this manual are assumed to be accurate at the time of this printing. Diamond Power International, Inc. reserves the right to change the content, product specification, and performance criteria without notice. Diamond Power accepts no liability for the inappropriate, negligent or incorrect setup of the equipment's operational parameters.

THIS INSTRUCTION MANUAL MAY DESCRIBE VARIABLE FEATURES NOT APPLICABLE TO YOUR SPECIFIC UNIT. THE PARTS IDENTIFICATION FORMS INCLUDED IN THE APPENDIX OF THIS MANUAL MAY ALSO INCLUDE VARIABLE OPTIONS OF THESE ASSEMBLIES.

Patents and Trademarks

THIS EQUIPMENT IS COVERED BY ONE OR MORE OF THE FOLLOWING PATENTS:

4,177,539 4,359,800 4,503,811 5,065,472 5,337,438

4,209,028 4,360,945 4,565,324 5,090,087 5,416,.946

4,218,016 4,375,710 4,567,622 5,135,198 5,437,295

4,229,854 4,422,882 4,803,959 5,167,307 5,509,607

4,351,082 4,492,187 5,048,636 5,320,073 RE-32,517

Copyright Notice

®MARCA REGISTRADA IN VARIOUS COUNTRIES

Table of Contents

SECTION 1 INTRODUCTION

1.1 Introduction 1-1

SECTION 2 CONTROLS AND OPERATION

2.1 General Information 2-1

2.2 Sootblower Operation 2-2

2.3 Motor Control 2-3

2.4 Local Operator Interface 2-3

2.4.1 Start Pushbutton

2.4.2 Motor Power Disconnect

2.5 Remote Control System Interface 2-4

2.5.1 Control Power (At) and Neutral (B)

2.5.2 Remote Start (D)

2.5.3 Sootblower Away From Rest (G) 2.5.4 Local Start Enable (A3) (Optional)

2.6 Typical Operation 2-4

2.6.1 Generallnformation 2.6.2 Sootblowing Permissives 2.6.3 Sootblower Starting 2.6.4 Sootblower Insertion 2.6.5 Sootblower Retraction

SECTION 3 INSTALLATION

3.1 Receipt of Equipment 3-1

3.2 Installation 3-1

3.3 Inlet Piping 3-2

3.4 Nozzle Setting 3-3

3.5 Blowing Arc 3-4

3.6 Mounting the Sootblower 3-5

3.7 Electrical Connections 3-5

3.8 Blowing Revolutions and Timer Setting 3-5

3.9 Adjusting the Limit Switch 3-6

SECTION 4 START~UP

4.1 Blowing Schedule 4-1

4.2 Cleaning 4-1

4.2 Start-Up Procedure 4-2

4.3 Initial Operation 4-2

SECTION 5 MAINTENANCE INSTRUCTIONS

5.1 Tools 5-1

5.2 Manual Operation 5-1

5.3 Timer Setting 5-1

5.4 Valve Maintenance 5-3

5.4.1 Adjusting the Blowing Pressure

5.4.2 Tightening the Valve Stem Packing

5.4.3 Replacing the Valve Stem Packing

5.5 Feed Tube Packing 5-4

5.5.1 Tightening the Packing Gland

5.5.2 Packing Replacement

5.6 Linear Nozzle Adjustment.. 5-6

5.7 Rotary Nozzle Adjustment 5-7

5.8 Drive Pin Replacement. 5-8

IM-15035 December 2004

1

Table of Contents

5.9 Nozzle Removal. 5-8

5.10 Front Bracket and Gear Assembly Removal 5-9

5.11 Screw Tube and Feed Tube Removal. 5-10

5.12 Guide Bar Pawl Removal 5-10

5.13 Guide Bar and Mounting Plate Removal 5-11

5.14 Motor and Gear Reducer Removal 5-11

5.15 Lubrication 5-12

SECTION 6 PREVENTATIVE MAINTENANCE

6.1 Recommended Maintenance Following First Month of Service 6-1

6.2 Six Months Service 6-1

6.3 18 Month Service 6-1

6.4 36 Month Service 6-1

SECTION 7 TROUBLESHOOTING

SECTION 8 STORAGE

8.1 General Information 8-1

8.2 Stacking Sootblowers for Storage 8-1

8.3 Sootblower Preservation 8-1

8.4 Electrical Equipment Storage 8-1

8.5 Diamond Power Liability 8-1

SECTION 9 PARTS IDENTIFICATION FORMS

IM-15035 2

December 2004

Section 1 Introduction

Control box and cover not shown.

Figure 1.1

IR-3Z SootbJower

1.1 INTRODUCTION

The Model IR-3Z Sootblower is a short travel, retracting sootblower, rotating 360 degrees and blowing through a predetermined arc controlled by the valve trigger and cam. Refer to an overall view on Figure 1.1. This sootblower is primarily used for cleaning furnace wall tubes.

The IR-3Z sootblower can be considered as consisting of six major sub-assemblies: (1) gooseneck valve assembly with trigger and feed tube, (2) drive unit (including motor, gear reducer, and pinion shaft), (3) front bracket assembly (including main drive gear), (4) guide bar and support plate assembly, (5) screw tube, packing and cam assembly and (6) the remote mounted control box. This general format will be followed throughout the instruction manual.

The gooseneck valve assembly contains an adjustable pressure control device and is the main supporting component of the sootblower assembly. Together with a stainless steel feed tube it conveys the cleaning fluid (either steam or air) to the screw tube and nozzle. Packing between the stationary feed tube and the rotating/translating screw tube prevents leakage caused by the movement of these components during sootblower operation.


1-1

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Section 1

Introduction

The drive unit operates the sootblower for the insertion, blowing rotation, and retraction of the screw tube and nozzle. The front bracket assembly attaches to the wallbox and supports the sootblower. It includes the main gear with drive pins for directing the screw tube and nozzle during operation.

A cam, located on the screw tube flange, actuates the valve trigger opening the valve for the desired blowing arc. This cam is cut to provide cleaning from 360 degrees down to 85 degrees. The required blowing arc can vary for individual sootblowers depending on their installed location to either clean a particular path or avoid an obstacle. The cleaning path can be directed by either the orientation of the nozzle or cam and can be adjusted after installation. A nozzle attached to the outboard end of the screw tube directs the cleaning fluid to the desired cleaning area.

The IR-3Z uses a remote mounted control box containing an adjustable timing relay. The timing relay controls the reversal of the sootblower cycle, either after 1, 2 or 3 cleaning revolutions. The control box interfaces with the sootblower via 2 cables, one for motor power and the other to the limit switch which controls operation. The lever-actuated limit switch is used to shut off power to the motor at the completion of the operating cycle and Signals the control system that the blowing cycle is completed. The limit switch also provides an assured means to detect the nozzle has been fully retracted from the boiler. The separately mounted control box mayor may not contain a motor starter.

Motor

Gooseneck

Adjustable Pressure Control V::Ilvp.

Screw Tube

Cam

FIGURE 1.2 Mode11R-3Z Sootblower

lM-15035 1-2

December 2004

Section 2

Controls and Operation

Limit Switch

The IR-3Z sootblower consists of the sootblower assembly that attaches to the boiler wall and a remote mounted control box. The control box contains a timer, terminal connections and may contain a disconnect and/or start button. The individual starter relay may be located in the control box or grouped in a main starter cabinet.


Remote Mounted ...........__

Control Box ..........

Figure 2.1

IR~3Z Sootblower with Control Box

The control box is remote mounted to allow ease of installation and access to the sootblower plus the control box can be located near main power cables and away from the high ambient temperatures around the boiler wall. The control box is connected to the sootblower with a power cable to the motor and a signal cable to the limit switch. The limit switch shuts off power to the motor atthe completion of the cleaning cycle and signals the sootblower control system that the nozzle has been fully retracted so the next sootblower in sequence may start. The adjustable control box timer will initiate the reverse relay to retract the nozzle after a set number of cleaning revolutions. The timer has a continuous

2.1 GENERAL INFORMATION

2-1

Section 2


operating temperature limit of 130°F (55"C) so the remote mounted control box should be located in a suitable temperature zone.

The electric motor drive on the IR-3Z sootblower typically consists of a 1/6 HP (124 watt) 1725 rpm motor revolving a 60: 1 wonn reduction gear box. The drive speed is further reduced 10:1 by the main drive gear. This results in a final nozzle speed of approximately 3 rpm.

Nozzle

Screw Tube

Cam

2.2 SOOTBLOWER OPERATION

The start of the sootblower cycle is either initiated by the sootblower control system or the locally mounted pushbutton on the control box. The forward relay will power the motor and the screw tube will leave the rest position inserting the nozzle into the boiler. During this forward travel the screw tube does not rotate, but is pulled to the forward position by the main drive gear. The travel is approximately 10.5 inches (27 cm). At the forward position the cam notch will disengage the guide bar and turns past the spring-loaded pawl allowing the screw tube and nozzle to rotate (clockwise).

The rotating cam will engage the poppet valve trigger, opening the valve allowing either steam or air to flow to the nozzle. Since the cam controls the flow, it can be cut to clean either a full or partial arc during the cleaning rotation. A partial cleaning arc is typically done to avoid an internal obstacle, opening or wall comer. The timer controls the number of revolutions (typically one pass) the nozzle will make during the cleaning rotation.


2-2

Section 2


After the cleaning rotation has completed, the timer will power the reversing relay and rotates the cam notch (counter-clockwise) until it engages the sprinq-loaded pawl. During this short reverse rotation the cam releases the poppet valve trigger shutting off flow to the nozzle. The pawl restricts further rotation and the cam notch will slide along the guide bar, retracting the nozzle out of theboifer. As the cam approaches the rest position it actuates the limit switch shutting off motor power and signaling the control system the sootblowing cycle has been completed.

It takes approximately 105 seconds for the IR·3Z to operate from start to rest position with one cleaning pass for a 60 Hz motor. Each additional cleaning pass will add about 20 seconds to the sootblowing cycle.

If during the sootbfowing cycle, the sootblower is subjected to an abnormal load such as binding in the wallbox sleeve due to the opening slagging shut from molten ash, the motor overloads will stop the sootblower, When this occurs before the rear limit switch has been actuated (a function which signals the panel that the normal blowing cycle has been completed), an elapsed time alarm in the control panel circuit will Signal the control system. In this situation, the control system cannot transfer to the next sootblower in sequence until the problem has been corrected and the overload reset.

The customer's motor power source is directed to the sootblower's motor via a motor starter. The starter may be provided at the sootblower, located remotely in a motor control center (MCC) or motor starter cabinet (MSC) supplied separately.

Optional motor starters supplied by Diamond Power are typicalJythe modular IEC type that conform to various IEC, UL, and CSA standards, and hold approvals from CE, CSA and UL. When requested, the IEC starters may be replaced with NEMA style starters (size 0 or 1).

2.3 MOTOR CONTROL (STARTER)

The starter may be a reversing or non-reversing type. Non-reversing starters are typically used in "master reversing" systems, in which the motor power source to multiple sootblowers is reversed upstream of the sootblower's individual starter by a "master reversing" contactor. Reversing starters, however, .. are more common and provide greater operational flexibility. Refer to the Elementary and Sootblciwer Wiring Diagram supplied by Diamond Power to determine if the sootblower comes equipped with a starter.

2.4 LOCAL OPERATOR INTERFACE

The local operator interface typically consists of the following devices mounted on the sootblower mounted terminal box.

2.4.1 Start pushbutton

Pressing the Start pushbutton will start the sootblower as long as control and motor power are present and other operating permissives are met. Controls external to the sootblower may vary. Occasionally, a local start permissive signal, "A3", is also required to be energized before a local sootblower start may occur.

2.4.2 Motor Power Disconnect

A disconnect switch is typically located on the terminal box, but may be excluded if it is not required by the customer. The disconnect switch must be the non-fused type, to prevent the possibility of single phasing the motor. Thermal overloads typically perform the motor over-current protection. If additional over-current protection is required atthe sootblower, the disconnect switch may be replaced with a 3- phase circuit breaker (optional). The disconnect switch or circuit breaker should be placed in the off position and locked or tagged out when servicing the sootblower and lance assembly. The power to the motor may also be isolated via the plug connector at the motor. Disconnecting the plug connector


2-3

Section 2


under load is not recommended. Isolate the upstream motor power source before disconnecting the plug at the motor.

2.5 REMOTE CONTROL SYSTEM INTERFACE

Terminations at the sootblower mounted control box provide the following inputs from and outputs to a central sootblower control system (not included). All inputs and outputs are at the designated control voltage (120 VAC is standard). Typical signals are listed below, but all signals may not be applicable to every sootblower. Refer to the Elementary and Sootblower Wiring diagram supplied by Diamond Power to determine exactly which signals are applicable to your application.

WARNING: The applied voltage at the inputs must be in phase and equal to the control voltage, "A 1 ".

2.5.1 Control Power (A1) and Neutral (8)

Single phase 120 VAC (50/60 Hz) is the standard control voltage. Alternate control voltage options are available upon request. The control power is typically supplied to the sootblower from the central sootblower control system to ensure signal compatibility. If an alternate control power source is supplied to the sootblower, interface signal power requirements should be carefully considered to ensure adequate power source isolation is maintained. An optional control power transformer (CPT) may be provided at the sootblower, if requested, to enable the control power to be derived directly from the motor power source as needed.

2.5.2 Remote Start (0)

Turning the "0" signal on momentarily (10 second pulse is typical) will start the sootblower if all permissives are met. For most applications, the "0" signal is energized by the central sootblower control system, and then it is "sealed in" through a limit switch contact and an auxiliary contact on the forward contactor. As such, the "0" signal may be used not only as a start command, but it may also be monitored to provide feedback to the central sootblower control system that the sootblower is traveling.

2.5.3 Sootblower Away From Rest (G)

The "G" signal is energized when the sootblower is away from the limit switch and remains on until it returns to the rest position. The "G" signal may be monitored by the central sootblower control system to indicate that the sootblower actually started and the cleaning cycle is in progress. The "Gil signal is hardwired through a contact on the limit switch.

2.5.4 Local Start Enable (A3) (Optional)

The optional "A3" signal may be included, if requested by the customer, to prevent unauthorized starting of the sootblower from the local start pushbutton. When used, the "A3" signal must be energized (120 VAC typical) from the central sootblower control system, to enable the local Start pushbutton. The "A3" signal is not typically included unless it is specifically requested.

2.6 TYPICAL OPERATION

2.6.1 General Information

Refer to the Sootblower Wiring and Elementary drawing(s) and Circuit Description supplied by Diamond Power to aid understanding of this section. Since some of the signals described in this manual are not used for every application, the drawings and circuit description should be used in conjunction with this manual to determine exactly which of the control interface signals described below are applicable. The operation description included below is intended to apply to most


2-4

Section 2


sootblowers that are controlled by a typical central sootblower control system manufactured by Diamond Power. If the sootblower control system is outdated or was provided by others, the description below might not be completely accurate for your application. Consult Diamond Power for more information as needed.

2.6.2 Sootblowing Permissives

Before a sootblower start may be initiated, certain permissives must be met. The blowing medium header must be adequately pressurized and the piping warm (warming is not applicable to sootblowers that use air as the blowing medium). In addition, there should be no standing alarms present that may prevent a sootblower start from being permitted

2.6.3 Sootblower Starting

A sootb!ower start may be initiated by momentarily completing the circuit between control signal terminals "A1" and "D". This may be performed locally via a start pushbutton mounted at the sootblower, or remotely via the central sootblower control system. The start pulse should be maintained long enough (10 seconds is typical) to permit the limit switch to operate.

2.6.4 Sootblower Insertion

When a sootblower start is initiated, it wiJl begin inserting the nozzles into the boiler. Once it moves away from the rest position, a contact in the limit switch closes to "seal inn the forward contactor coil through the forward contactor's normally open auxiliary contact. Also when the limit switch closes, a timer is triggered to time the forward travel. The timer may be set to allow one, two, or three blowing revolutions.

2.6.5 Sootblower Retraction

When the forward travel time is complete, a timer contact in the forward contactor circuit will open causing the forward starter to de-energize and the reverse contactor to energize. The sootblower will then travel in reverse until it reaches the rear limit switch which will open and de-energize the reverse contactor. The Sootblower is then back at rest and ready for the next operation.

IM-15035 Decem ber 2004

Section 3 Installation

3.1 RECEIPT OF EQUIPMENT

Before beginning installation, locate each sootblowerfor it's specific location. It is important to match the correct sootblower for each specific location because it will be built with specific features to clean that location. Installation drawings are provided with each order to show the location of each sootblower. A sootblower installation includes the following components:

1. IR-3Z sootblower.

2. Wal1box assembly.

3. Remote mounted control box.

\ Limit Switch Junction Box

Boiler Tube

Scavenging Air -......_____ Companion Flange

-......_____ Inlet Piping

Figure 3.1

Basic Installation

3.2 INSTALLATION

A ,complete set of installation drawings and instructions specific to each customer are provided with every contract. The basic installation of an lR-3Z sootblower consists of the following:

1. Installation of the wall box sleeve between the boiler tube opening.

2. Wal1box is welded to sleeve. Wallbox may consist of either a cast seal box (required for positive pressure boilers) Of just simply a mounting flange (negative or balanced draft boilers).

3. Companion flange welded to inlet piping.

4. Position the nozzle for the required blowing arc as required before mounting sootblower.

5. Mount the sootblower in position. Bolt to wal1box and companion flange.

6. Sootblower is not shipped from factory with lubricant in the motor gear reducer. Refer to Section 5.15 and fill with the proper lubricant.

7. For positive pressure bailers, an air source must be connected to the wall box and scavenging air line to the poppet valve.

8. Attach the remote mounted control box. Connect the source power for the motor plus the


3-1

Section 3

Installation

control power to the remote mounted control box. Connect the motor power and control signal cable to the limit switch junction box. See customer specific installation instructions.

The IR~3Z sootblower can be mounted in a variety of positions to either avoid obstacles outside the boiler or to mate up with existing piping. Figure 3.2 shows the rear profile of the IR·3Z in various mounting positions.

Mounting Position "A"

Mounting Position "C"

Mounting Position "8"

Mounting Position "C-S"

Mounting Position "0"

Mounting Position "E"

3.3 INLET PIPING

Figure 3.2

Mounting Position

The emergency stop valve on the boiler and the piping to the sootblowers must not be less than the size specified on the installation drawing. To promote proper drainage of condensate, all steam piping must have a pitch of at least % inch per foot (4 cm per meter or 2.5 degrees) toward the discharge end of the drain line.

Any steam blowing IR~3Z sootblower with its valve installed more than 450 off vertical centerline requires a condensate drain line. The drain line relieves the condensate which would otherwise be trapped between the valve seat and the companion flange. This drainage prevents condensate buildup in the valve which can contribute to corrosion and increased condensate carryover at the start of blowing. The drain line enters the companion flange via a socket weld connection. The drain line should be covered by insulation to avoid hazard to personnel. Refer to installation drawing for drain line configuration.

All piping is to be blown clear of all foreign matter before connecting to and operating the sootblowers. Separate the flanges at the sootblower connection to the piping and insert a sheet metal deflector between the flanges during the blowing out process. This is to ensure that dirt, scale, or welding beads from the piping system does not enter the sootblowers and damage the valve seat.

IM-150;35 December 2004

3-2

Section 3

Installation

Piping must be designed to prevent undue strain on the sootblower. The IR-3Z sootblower is supported by the wallbox attached to the boiler wall and the sootblower will move as the boiler expands. The boiler wall must be able to support the weight of the sootblower plus any additional piping loads. The approximate sootblower weight is 225 Ib (100 kg) and the maximum allowable piping loads are shown in Figure 3.3.

+Fy

INDIVIDUAL PIPE LOAD LIMITATIONS

CENTER OF VALVE POT FLANGE

LOAD LIMITATION
+ DIRECTlON - DIRECTION
Fx 1000 LBS 1000 LBS
Fy_ 1350 LBS 630 LBS
Fz 1975 LBS 910 LBS
Mx 1100 FT-LBS 2390 FT -LBS
Mv 1745 FT-LBS 1745 FT-LBS
Mz 1710 FT-LBS 1710 FT-LBS COMBINED PIPE LOAD LIMITATIONS [(2.41FX + 1. 38My f + (I.38Mz + Fx)2]'2 :5: 3240

[ 2 2 ]1/2

t(2.4IFy + 1.66Fz - 1.38Mx) + (Fx + 1.38Mz) :5: 2354

Figure 3.3

Pipe Load Limitations

3.4 NOZZLE SEITING

Before the sootblower is installed the nozzle position should be set so that it extends far enough into the boiler to provide proper cleaning. Refer to Figure 3.4 and follow the procedure below:

1. Measure the distance from the outside face of the wallbox flange to the inside face of the boiler wall tubes. This will be dimension "A".

2. Add 1.5 inches (38 mm) to dimension ~A" to get dimension "B", The centerline of the nozzle should be 1.5n (38 mm) past the face of the boiler wall tubes.

3. Extend the screw tube to its forward position either with power to the motor or manually, see Section 5. Loosen the nozzle locknut and adjust the nozzle for the required length "B".

4. Refer to the installation drawings for each sootblower and determine if it has a specified blowing arc. If is does then the nozzle will have to be positioned so that it cleans the proper path once it is installed. Continue to operate the sootblower until the cam contacts the trigger. The moment the leading edge of the cam contacts the trigger the poppet valve will begin to open. Rotate the nozzle so it's position coincides with the installation drawing for start of blowing. Operate the sootblower and check the position of the nozzle as the trigger opens and closes the poppet valve. If it is necessary to adjust the blowing arc, then the cam may have to be cut, refer to directions in Section 3.5.

5. Tighten the nozzle locknut and tack weld to both the nozzle and screw tube.

6. Install the sootblower on the wallbox and operate it.several times to check for interference between the nozzle and wallbox sleeve. Any interference will suggest a misaligned wallbox flange with respect to the sleeve.

7. Check the position of the nozzle while the trigger holds the poppet valve open to ensure full cleaning coverage as prescribed by the installation drawing. It is possible to adjust the position of the cam to change the cleaning path after the nozzle has been positioned and the sootblower installed.


3-3

Section 3

Installation

1.5 INCHES --~ (38 mm)

usn

Screw Tube

TRAVEL 10.5 INCHES (27 em)

3.5 BLOWING ARC

Figure 3.4

Nozzle Position

For cleaning flexibility, the IR-3Z may be supplied with two different trigger/cam configurations, or with a custom cam for a specific cleaning path, Refer to the installation drawings for each location.

360 Degree Blowing Arc

For full 3600 blowing, the OEM cam and trigger combination supplied does not require alteration. The cam covers 3270 of blowing rotation whife the trigger provides the remaining 33° of overlap holding the valve open.

Standard Blowing Arc of 295 Degrees

If the sootblower is ordered with the "standard" cam and trigger, the configuration provides a 2950 blowing arc. The cam covers 2400 of rotation while the trigger provides the remaining 550 of overlap.

Reduced Blowing Arcs

When it is necessary to clean less than 295" then the standard cam can be modified for a shorter blowing arc. Cams with shorter blowing arcs are available in increments of 5° (see the parts identification forms in the Appendix). Cams can also be cut in the field for the prescribed blowing arc. The easiest way to determine the length of the cam is to position the nozzle in the start blowing position when the cam first contacts the trigger. Now operate the sootblower through the desired


3-4

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Section 3

lnstatlatlon

blowing arc and stop it. Mark the cam flange at the nose of the trigger and remove the cam. Subtract off 2.5 inches (64 mm) from this position as the trigger will hold open the valve for 55° of the rotation until it drops off the cam, closing the valve. Cut away only the portion of the cam that contacts the trigger, the flange is required for mounting to the screw tube flange. The cam should never be cut less than 27°.

3.6 MOUNTING THE SOOTBLOWER

Once the wallbox flange and the companion flange have been installed and the nozzle adjusted the sootblower should be ready to mount.

1. Attach the sootblower to the wallbox flange using the 5/8-11 bolts.

2. With the gasket between the poppet valve and companion flange, hand tighten the nuts around the flange. In a crisscross pattern tighten the nuts until the gasket is compressed until the flange faces contact the gauging ring on the gasket. Uneven tightening could deform the gasket making it impossible to obtain a satisfactory seal.

A\ CA UTION. Do not over-tighten the nuts. Approximate torque values when properly ~ tightened will be 175 foot-pounds (235 Nsm).

3. Ensure that the air relief valve is mounted in an upright position. On negative pressure or balanced draft boilers, atmospheric pressure typically provides a sufficient flow of air through the air relief valve to purge corrosive boiler gases. Positive pressure boilers will need to have an air source connected to the air relief valve to force boiler gases out of the valve, feed tube and screw tube. The scavenging air pressure should be 4-6 inches H20 (1-1.5 KPa) above the boiler pressure.

4. Positive pressure boilers also require seal and aspirating air connected to the walibox. Seal air will pressurize the chamber around the nozzle sealing in the boiler gases. Aspirating air seals the wallbox while the screw tube and nozzle are removed. Seal air pressure should be a minimum of 3 inches H20 (.75 KPa) above the boiler pressure. Aspirating air should be an 80-100 psig (5.5-7 bar) air connection to the wallbox. Be certain to energize the aspirating air when removing the screw tube with the boiler online.

3.7 ELECTRICAL CONNECTIONS

The design, supply, and compliance of the field wiring with local, state and national codes are the responsibility of others and are not the responsibility of Diamond Power. Cable must be adequately sized for the maximum current that the source breakers may provide, regardless of the downstream load. Refer to the customer specific schematic interconnecting wiring diagram to make the appropriate connections.

3.8 BLOWING REVOLUTIONS AND TIMER SETTING

The number of blowing revolutions the sootblower makes is set by the timer in the remote mounted control box. The timer controls when the motor is reversed so there is some addition operating time to retract the nozzle from the boiler to the rest position. For most cleaning applications one cleaning pass is all that is required to adequately clean the boiler wall tubes. See the chart on the following page for the timer settings and Section 5 for adjusting the brewing time.


3-5

Section 3

Installation

Timer Setting
60 Hz Electric Motors 50 Hz Electric Motors
Blowing Timer Setting Operating Time Timer Setting Operating Time
Revolutions
1 62.3 seconds 105 seconds 75.0 seconds 126 seconds
3 102.7 seconds 146 seconds 124.0 seconds 175 seconds 3.9 ADJUSTING THE LIMIT SWITCH

The sootblowing cycle is completed when the nozzle is fully retracted out of the boiler and the cam on the end of the screw tube engages the limit switch operator, shutting off power to the motor. The operator rod on the limit switch may need adjusted to provide adequate clearance for the packing gland. In the rest position there should be a minimum gap of .0625 inch (1.6 mm) between the packing gland and feed tube bolts, refer to Figure 3.5. The operator rod will need to be adjusted to allow for about %: inch (13 mm) of travel once the cam initially engages the operator rod.

Limit Switch

Operator

0.625 inch (16 mm) Minimum

Limit Switch Operator Adjustment

Figure 3.5

IM~15035 December 2004

3-6

Section 4 Start-Up

4.1 BLOWING SCHEDULE

The normal recommended practice is to clean the boiler in the direction of gas flow and from the top down. The units near the furnace operate first, followed by the superheater and economizer units. If it is anticipated that very heavy accumulations must be removed, a few of the units in the rear passes should be operated interchangeably with those in the first pass of the boiler. This will eliminate a heavy accumulation in the boiler outlet area. If a straight through schedule were employed, it is conceivable that accumulation removed from the superheater region would pile up in the economizer area. These recommendations are simply general; operating experience with the individual boiler will be the most accurate guide.

Sootblowers are generally used on boilers of relatively high capacity, but can be used on smaller boilers. The larger capacity boiler is normally large enough in furnace volume that the amount of cleaning medium blown into it is a small percent ofthe gases passing through it. On a smaller boiler, the amount of cleaning medium blown into it could be large enough to cause "puffing" or agitation of combustibles which might accumulate in pockets and behind baffles. Sootblowers used on smaller boilers must be operated with caution to prevent the danger of puffing or furnace explosion. With the larger boilers, these precautions are not normally necessary.

Precautions should be taken on smaller boilers to ensure that the boiler is at a capacity of more than 50 percent, and draft fans are operating at a: high rate of flow. If agitation of combustibles occurs, this will assure they are carried through the boiler at a rapid rate. If the firing rate is low, puffing or furnace explosions are possible.

4.2 CLEANING

The IR-3Z sootblower is typically equipped with one nozzle and is capable of cleaning a pattern that is oval in shape, usually 10 feet (3 meter) high by 8 feet (2.4 meter) wide. The cleaning radius is affected by the slagging characteristics of the ash. Ash with a low melting point is more difficult to clean and will decrease the cleaning radius to about 8 feet (2.4 meter) high by 6 feet (1.8 meter) wide. The purpose of sootblowing is to remove deposits from the boiler wall tubes to improve heat transfer which will lower the gas stream temperature. As the boiler gas temperature rises, the ash can turn semimolten and prove very difficult to remove.

Typically, the IR-3Z sootblower is set for one cleaning revolution, but for harsh cleaning applications such as molten ash it may be necessary to set it for two or three cleaning passes to effectively clean the boiler tubes. The purpose of the additional cleaning passes is to first solidify the ash by cooling it and then to knock it off the boiler tubes with additional passes. Two or more cleaning passes should be used with caution, if the boiler wall is effectively cleaned on the first pass then there is potential damage with tube erosion. Increasing operating frequency or blowing pressure is generally more effective than increasing the number of blowing revolutions.

The blowing arc of the IR-3Z can be restricted to avoid inter~al obstacles such as the burner box area or an adjacent boiler wall. Blowing directly at an adjacent wall at the sharp angle the IR-3Z nozzle is directed can cause erosion. It is best to not directly clean on a target that is nearer than 4 feet (1.2 meters). Contact Diamond Power for any special cleaning applications.


4-1

Section 4

Start~Yl?

4.3 START-UP PROCEDURE

WARNING: Ensure power is disconnected to the so otb/ower before performing any checks or beginning the start-up procedure. Prior to energizing any electronic control panel, all field wiring must be meggered to ground. Isolate steam/air

source before perlorming any checks prior to operation.

1. After the installation of hardware and field wiring and before applying power to the sootblower, carefully inspect it's installation.

2. Verify that all mechanical parts are free from binding and that no tools or equipment are in a position to be struck by any moving part.

3. Before allowing any flow to the poppet valve, ensure the companion flange gasket is properly compressed and all ports are tightly sealed. Check the packing gland to ensure it is not loose.

4. Ensure the main motor gear reducer has been filled with lubricant, see Section 5.

5. Inspect the electrical connections to ensure the proper voltages are connected to the remote mounted control box and verify with the wiring diagrams that it has been properly wired to the motor and limit switch on the sootblower. Ensure all wire connections are tight and components are properly grounded.

6. Check that the timer in the remote mounted control box is properly set to achieve the desired blowing revolutions. See Section 3 installation instructions for timer setting.

1.\ CA UTION. To prevent damage to the nozzle, do not operate the sootblower without ~ proper steam/air pressure with the boiler online.

7. Apply power to the control box and sootblower and operate it locally from the remote mounted control box. Watch it's operation to ensure the screw tube inserts easily and that the cam properly engages the poppet valve trigger. Ensure the poppet valve closes upon retraction and limit switch shuts off power when the screw tube reaches the rest position,

8. For positive pressure boilers ensure that an air source has been connected to the scavenging air line for the poppet valve and seal air to the wallbox.

4.4 INITIAL OPERATION

WARNING: Before allowing the sootblower to operate with steam, ensure the poppet valve has been properly attached to the supply piping. Check the connections on the poppet valve and that the feed tube packing gland has been

properly tightened. The sootblower will become very hot during operation, ensure the safety guards are in place and are only removed for maintenance or inspection and then re-installed.

1. With the boiler online and the steam/air source open to the sootblower the blowing pressure will need to be set. The poppet valve contains an adjustable pressure control which is only opened to it's lowest setting at the factory. Instructions are given in Section 5 for adjusting the blowing pressure. The proper pressure settings are determined specifically for each location and are shown on the installation drawings provided by Diamond Power.

2. It is recommended to operate the sootblower from both the sootblower control system and locally at the remote mounted control box.

3. During operation check the sootblower for any steam/air leaks.

4. Check the operation of the cam and trigger to ensure the poppet valve opens for the set number of revolutions and fully closes. Upon retraction, the cam should engage the limit switch and shut off the sootblower.

5. Check that the air relief valve is functioning. It will draw in air on negative pressure boilers.

Pressurized air must be attached for positive pressure boilers.

6. Check the sealing air at the wall box for positive pressure boilers.

7. The sootblower is now ready to be placed into service.

I

- l

. ~:~'7"'E~~.",,·-·J


4-2

Section 5

Maintenance Instructions

WARNING: Before performing any maintenance, disconnect power to the control box and soothlower to prevent automatic operation or chance of electrical shock. Isolate any steam/air to the sootb/ower and operate the valve trigger to release any

trapped pressure between the isolation valve and poppet valve. Caution should be employed around sootb/owers because they may be very hot from a recent operation and it is possible for steam to leak past valves.

5.1 TOOLS

Most maintenance can be performed on Diamond Power sootblowers using standard tools found in a typical mechanic's toolbox. Occasionally special tools are needed to perform certain functions depending on the level of maintenance.

The poppet valve requires a spring depression tool to compress the valve stem spring in order to disassemble the poppet valve. A valve adjusting wrench is also used to adjust the tightness of the packing nut. Refer to PI-4339 in the Appendix for part numbers for these tools. If poppet valves are going to be rebuilt on site requiring the removal of the seat and disc then special tools are required to perform the seat installation, refer to PI-3312 in the Appendix

5.2 MANUAL OPERATION

CAUTION. Do not apply excessive force to manually operate the sootb/ower. Do not use an impact wrench on the square tang as it is capable of damaging the gear drive mechanism and will void the warranty. If there is excessive resistance when

manually operating the sootb/ower it may be due to some other components binding. Do not fully insert nozzle into online boiler without steam/air flow through valve for cooling.

The sootblower may be manually operated during set-up or to perform maintenance. There is a square tang on the main motor gear reducer to attach either a ratchet, electric drill or air wrench.

Disconnect the motor power source before manually operating the sootblower. The end of the gear reducer opposite the motor end has a square tang for manually driving the screw tube and nozzle assembly. A standard electric drill or air-powered (non-impact) wrench with a 7/16 inch - 12 point socket is suitable for driving the square tang. Rotating the square tang counterclockwise wlll move the screw tube and nozzle forward. Clockwise rotation of the square tang will retract the screw tube and nozzle. Before re-connecting the motor power source, fully retract the screw tube manually until the limit switch operating lever is actuated.

5.3 TIMER SETTING

There is a timer (relay) in the remote mounted control box that controls the number of cleaning passes (revolutions) the nozzle makes before reversing. Typically sootblowers are set-up for one cleaning revolution but more may be necessary for harsh cleaning applications.

For sootblowers configured for 3600 blowing it is important the timer be set for the cam to make a full revolution and the trigger to drop off the cam and close the valve before reversing. This allows the notch in the cam to properly engage the guide bar when it reverses. The optimum reversal point for the motor is after the cam has completed a full rotation, the opening in the cam has rotated past the


5-1

Section 5

Maintenance instructions

trigger, and the cam re-engages the trigger such that a small portion of the trigger face is on the cam surface. This reversal point permits the trigger to "back-off' the cam through the cam opening, allowing the cam flange notch to pick up the pawl and keep "blowing over-travel" to a minimum.

Setting the Sootblower Timing

1. Disconnect the motor and control power source.

2. Open the cover on the remote mounted control box to gain access to the adjustable timer.

3. On the timing relay, set the range adjustment knob to 0.1 second increments. Set the time according to chart below:

Timer Setting
60 Hz Electric Motors 50 Hz Electric Motors
Blowing Timer Setting Operating Time Timer Setting Operating Time
Revolutions
3 102.7 seconds 146 seconds 124.0 seconds 175 seconds Figure 5.1

Timer Setting

4. Close the cover on the control box and reconnect the power source to test-run the sootblower. As the sootblower is operated, the screw tube will travel forward until the fully extended position is reached. In the fully extended position, the screw tube rotates clockwise permitting the cam to engage the trigger.

5. Ifthe motor does not reverse at the desired paint, disconnect the power and adjust the timing relay as needed.


5-2

.... ~._'~I_;:$;.~_-

Section 5


Standard Blowing with 360° Cam and Trigger

Occasionally, it is necessary to reduce the blowing arc to less than 360°. This is simply done by decreasing the set time on the timer relay inside the control box. The motor will reverse sooner once the nozzle has reached the end ofthe desired blowing arc. It should be noted with this type of blowing that cleaning will be performed in both directions.

5.4 VALVE MAINTENANCE

WARNING: Disconnect power to the control box and sootblower to prevent automatic operation before performing any maintenance. Isolate any steam/air to the sootblower and operate the valve trigger to release any trapped pressure

between the isolation valve and poppet valve. Caution should be employed around sootblowers because they may be very hot from a recent operation and it is possible for steam to leak past valves.

Plug

Lock Pin Plug

Valve Spring

Packing Washer

Retainer Plate

Figure 5.3

Poppet Valve Section View

5.4.1 Adjusting the Blowing Pressure

The sootblower is equipped with an adjustable pressure control disc on the downstream side of the poppet valve seat. This is the means for adjusting the blowing medium supply pressure to the desired blowing pressure. This pressure control disc is opened approximately one turn at the factory during assembly and must be set in the field. It is recommended to periodically check the blowing pressure to ensure the necessary flow is achieved for proper cleaning. Refer to the installation drawings for proper pressure settings.


5-3

Section 5


Refer to Figure 5.3 for a sectional view of the poppet valve.

1. Install the pressure gauge at an appropriate connection on the poppet valve, if it has not been done already. If possible, install a piping pigtail filled with water to help isolate the pressure gauge from the steam.

2. Operate the sootblower and note the blowing pressure.

3. After the blowing cycle and the poppet valve has been shut off, remove the lock pin plug from the other side of the poppet valve.

4. Insert a screwdriver into the poppet valve and rotate the pressure control disc.

• Clockwise rotation decreases pressure.

• Counter-clockwise rotation increases pressure.

5. Lubricate the threads on the lock pin with high temperature anti-seize before installing on the poppet valve and tighten. NOTE: Be certain the flutes ofthe control disc are aligned with the lock pin before tightening.

6. Start the sootblower and check the pressure.

7. Repeat as necessary in order to obtain proper blowing pressure.

8. When completed, torque the poppet valve plugs to 60 ft-lbs (81 N-m).

5.4.2 Tightening the Valve Stem Packing

Using the valve stem adjustment wrench (PIN 312227-1129), turn the packing nut beneath the valve spring in a clockwise direction. Tighten only enough to prevent leakage, approximately 10 ft-lbs (14 Nm) max. Over-tightening will shorten packing life, make pressure adjustment more difficult and possibly cause stem binding. See Figure 5.3.

5.4.3 Replacing the Valve Stem Packing

Reference Figure 5.3 and the parts identification forms in the Appendix for a detailed view of the poppet valve.

1. Disconnect steam source and isolate.

2. Operate the poppet valve manually to release any trapped steam.

3. Remove trigger.

4. Using the spring depression tool, depress the valve spring enough to permit removal of the

yoke on the internal adjustable poppet valve.

5. Release spring tension slowly.

6. Lift off the spring retainer plate and valve spring.

7. Unscrew the packing nut and remove packing washer and packing.

8. Replace with new packing, seating each ring separately with the packing washer.

9. Replace an parts in reverse order.

10. Tighten the valve stem packing nut as instructed in Section 5.4.2.

11. Return sootblower to service and observe operation.

5.5 FEED TUBE PACKING

WARNING: Disconnect power to the control box and sootblower to prevent automatic operation before performing any maintenance. Isolate any steam/air to the sootblower and operate the valve trigger to release any trapped pressure

between the isolation valve and poppet valve. Caution should be employed around sootblowers because they may be very hot from a recent operation and it ;s possible for steam to leak past valves.

Feed tube replacement packing is available in either graphite foil or teflon. The type of packing used is based on the operating temperature parameters and maintenance preference.


5-4

Section 5


Graphite packing is typically used for steam blowing but is ideal for air as well. Graphite foil packing rings are conical and the conical shape is pointed towards the operating pressure for sealing. Graphite foil packing is available in both solid-rinq and split-rlnq. The split-rlnq packing is easier to replace but will generally have a shorter service life. When replacing, it is recommended that the complete packing set be replaced for maximum service life.

Teflon packing is designed to be self-enerqized by the operating pressure. Thus, the two sealing lips of each ring are to be pointed towards the operating pressure and the packing only needs a small preload to maintain a seal. Teflon packing should be used with a feed tube that is in good condition. Teflon packing is generally used for air blowing but is acceptable for steam service is the steam source is less than 500°F (260°C). Teflon packing is split-rinq so it is easy to replace. When replacing it is recommended that the complete packing set be replaced for maximum service life.

Packing Gland

Adjusting Nuts


5~5

Figure 5.4

Packing Gland Assembly

5.5.1 Tightening the Packing Gland

Over time the packing will wear and eventually leak during operation. If the packing develops a slight leak and take-up distance exists between the packing gland and flange on the screw tube, tighten the gland evenly and alternately advancing the packing adjustment nuts. Refer to Figures 5.4 and 5.5. Tighten only enough to prevent leakage. Over-tiqhtenlnq will shorten the packing life.

5.5,2 Packing Replacement

1. Advance screw tube approximately % inch (13 mm) from rest position.

2. Remove packing adjustment nuts. Refer to Figures 5.4 and 5.5.

3. Advance the screw tube an additional 4 inches (1 00 mm) and slide packing gland back. This forward motion will loosen packing within the packing chamber.

4. Using a packing removal tool, remove each individual ring of the packing set. Ensure that all rings are removed.

5. Insert new packing with proper orientation, one ring at a time. Spllt-rinq packing Should have the splits staggered 1800 apart.

Section 5


6. Start packing gland into packing chamber and attach the adjustment nuts. Evenly, and alternately tighten the nuts until packing is snug. Operate the sootblower to check for leaks and retighten if necessary. Tighten only enough to prevent leakage. Over-tightening will shorten packing life and add unnecessary load to sootblower drive components.

1.\ CA.UTION. The packing adjustment nuts must not extend past the studs or there is L.l.l the risk of hitting the feed tube bolt heads.

Feed Tube

Screw Tube Flange

Figure 5.5

Feed Tube Packing Gland

5.6 LINEAR NOZ,?:LE ADJUSTMENT

The distance the nozzle is inserted into the boiler can be adjusted after the sootblower has been installed and the nozzle tack welded to the screw tube. The nozzle is set near mid-point of its adjustment at the factory to permit 1/2 inch (13 mm) either forward or reverse.

Increase Insertion

1. Move the inside adjustment nuts forward the distance equal to the desired nozzle adjustment.

Refer to Figure 5.6.

2. Advance the outside nuts alternately causing the cam assembly to move back until stopped by the inside nuts. This will permit the screw tube and nozzle to advance farther into the boiler.

3. Tighten the inside and outside nuts against the packing chamber flange to secure the setting.

4. To maintain the same motor reversal point, it may be necessary to adjust the setting on the timing relay. See Section 5.3 for timing adjustments.

Decrease Insertion

1. Move the outside adjustment nuts back the distance equal to the desired nozzle adjustment.

Refer to Figure 5.6.

2. Turn the inside nuts alternately causing the cam assembly to move forward until stopped by


5-6

Section 5


the outside nuts. This will restrict the travel of the screw tube and stop the nozzle closer to the wall tubes.

3. Tighten the inside and outside nuts against the packing chamber flange to secure the setting.

4. To maintain the same motor reversal point, it may be necessary to adjust the setting on the timing relay. See Section 5.3 for timing adjustments.

Packing Chamber Flange

5.7 ROTARY NOZZLE ADJUSTMENT

The cleaning pattern can be changed by repositioning the cam around the screw tube, refer to Figure 5.6. Holes in the flange assembly are 20° apart; therefore, movement of the cam from one hole to the next will reposition the nozzle accordingly. In some situations, you will need to slightly lead or lag the ideal nozzle position.

1. With sootblower at rest position and cam flange notch engaged on guide bar, remove the pin

on the drive pinion shaft coupling. <

2. Remove the six cam retaining screws and remove the un-notched half of cam while holding the notched half in contact with guide bar to perform the next step.

3. Apply rotary motion to the screw tube (by hand or strap wrench) until the nozzle is in the desired new position.

4. Replace the cam halves and secure the retaining screws. (The cam flange notch must stilt be on the guide bar.)

5. Replace the pin in the drive pinion shaft coupling. If the pin hole in pinion shaft is not in line with the hole in coupling, rotate slightly in either direction until holes align.

_,-.,."':


5~7

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Section 5


5.8 DRIVE PIN REPLACEMENT

The IR-3Z sootblower is equipped with four drive pins in the main drive gear for guiding the screw tube during operation. Refer to Figure 5.7.

1. To remove each drive pin. bend locking washer from the drive pin retaining screw.

2. Remove screw and lock tab washer.

3. Thread a #8-32 screw into the center of each pin for removal.

4. When replacing each drive pin, ensure that the pin engages with slot in screw tube. For maximum service life, all drive pins should be replaced at the same time.

5. Replace retaining screw and washer. Screw must tighten flush with main gear hub.

6. Bend the locking washer to complete the locking procedure.

i-- Drive Pin Retaining Screw @ ----- Locking Washer ~~~;;::----__ Drive Pin

Figure 5.7

Drive Pins

WARNING: Disconnect power to the control box and sootblower to prevent automatic operation before performing any maintenance. Isolate any steam/air to the sootb/ower and operate the valve trigger to release any trapped pressure

between the isolation valve and poppet valve. Caution should be employed around sootblowers because they may be very hot from a recent operation and it is possible for steam to leak past valves.

5.9 NOZZLE REMOVAL

1. Disconnect motor power and isolate steam supply. Remove sootblower.

2. Mark the cam flange to coincide with the nozzle centerline position. Make certain that the mark on the threaded spindle and nozzle centerline coincide.

3. Measure the distance from the end ofthe nozzle to the front end of the threaded spindle. This establishes the correct position of the nozzle when replaced.

4. The nozzle assembly may be removed by cutting the tack-weld, loosening the locknut, and

IM-1S035 December 2004

5-8

Section 5


unscrewing the nozzle assembly.

5. When replacing the nozzle, make certain it is properly located, then tighten the locknut to secure it's position. Tack-weld the locknut to both the nozzle and screw tube.

Seal Ring

Front Bracket ~

" First Retaining Ring

" Main Drive Gear

Front Bracket and Gear Assembly

5.10 FRONT BRACKET AND GEAR ASSEMBLY REMOVAL

Figure 5.8

Refer to Figure 5.8 to remove the main drive gear, front bracket and bearing.

1. Disconnect motor power and isolate steam supply. Remove sootblower from wallbox.

2. Remove the main gear cover.

3. Remove drive pins from main drive gear.

4. Remove the two retaining screws on front of guide bar plate.

5. Remove the two retaining screws at base of front bracket assembly.

6. Withdraw the front bracket and gear assembly leaving the screw tube in place.

7. Place front bracket assembly with wallbox mounting flange down and locate the opening in the first retaining ring through the openings in the main drive gear.

8. Using a retaining ring tool, remove the retaining ring from its groove.

9. Lift main drive gear and bearing together from the bracket assembly. This is a slip fit and will not necessitate forcing unless a corrosive condition exists.

10. To separate bearing and gear, remove the second retaining ring and lift off bearing. The bearing also slip fits on the gear.

11. Replace in reverse order. Ensure that the retaining rings are seated in their grooves.


5-9

Section 5


5.11 SCREW TUBE AND FEED TUBE REMOVAL

1. Disconnect motor power and isolate steam supply. Remove sootblower from wallbox.

2. Remove front bracket and gear assembly (see Section 5.10).

3. Remove poppet valve trigger and front pawl on guide bar.

4. Pull screw tube assembly forward off the feed tube. It may be necessary to loosen the packing pre-load.

5. The feed tube can be removed at this time if necessary.

6. If feed tube is removed, The gasket will usually adhere to the gooseneck. Carefully clean the surfaces thoroughly and replace gasket. Apply heavy duty anti-seize lubricant to the threads and alternately and equally tighten screws to 55 ft-lbs (75 N-m). Note that the bottom 2 holes penetrate the pressure cavity.

7. Replace in reverse order.

5.12 GUIDE BAR PAWL REMOVAL

/ Motor & Gear Reducer Support Bracket

Pawl Retainer Nut

Limit Switch Mounting Plate \

" Guide Bar Support

Bracket

Pawl Spring

B

~ '" Pawl Spacer

i'" <, Pawl

U-- Pawl Retainer Screw

Figure 5.9

Guide Bar Assembly


Section 5

. . ,.

·.··_,,·' •. _".c ••• , •• ,._ •• "'.~ _ ... _ .•• _.,' _._ •• , .••. ,. _ •.••••• __ ._ •..• _.


The front pawl may be removed without removing the guide bar plate (Refer to Figures 5.9 and 5.10).

1. Remove the guide pawl spring.

2. Remove the pawl retaining screw and nut.

3. Pull the pawl assembly down out of its housing.

4. Reinstall in reverse order.

CAUTION. When installing a new pawl, ensure that the end of the pawl does not project from the guide bar face in excess of .06 inch (1.5 mm). Refer to Figure 5.10. If necessary, grind off angled face slightly to reduce projection.

Figure 5.10

Pawl and Guide Bar Alignment

5.13 GUIDE BAR AND MOUNTING PLATE REMOVAL

1. Disconnect motor power source. Remove rear limit switch from limit switch mounting bracket.

2. With sootblower at rest position, remove the flat socket head cap screws from the underside ofthe mounting plate. Remove the roll pin connecting the guide support bracket to the guide bar mounting plate.

3. Remove the guide bar and mounting plate assembly out left side of sootblower.

4. Replace assembly in reverse order. When assembling rear limit switch on bracket, make sure that the limit switch operating lever is actuated by the cam flange in the rest position.

5. The guide bar can be removed for replacement independently of the mounting plate by removing the two cap screws that secure the bar to the plate.

5.14 MOTOR AND GEAR REDUCER REMOVAL

The motor and gear reducer can be removed as a unit as follows:

1. Disconnect the power source.

2. Remove the conduit box mounting bracket from the rear of the gear reducer.

3. Remove the shield and a roll pin from the drive pinion shaft.

4. Remove the 3/8" cap screw which secures the gear reducer to the mounting bracket.

5. The drive assembly can now be removed and the coupling will pass through the bracket.

6. Replace parts in reverse order.


5-11

Section 5


I Roll Pins ->

3/8" Cap Q/"

Screw ~

~ n V \ Drive Shaft

a

\ \ Coupling

Gear Reducer Mounting Bracket

I

Motor Adapter Flange

Figure 5.11

Gear Reducer Assembly

5.15 LUBRICATION

~ CAUTION. The sootblower is shipped without lubricant in the motor geaMeducer ~ and should be filled with the proper type and amount before operating sootblower.

The warranty will be void if these instructions are not followed.

The only components on the IR-3Z sootblower requiring lubrication is the motor gE:l;ar reduc~.r,;iJ:he IR- 3Z sootblower is shipped without lubricant in the motor gear reducer. All other components nave been properly lubricated at the factory prior to shipment.

Fill the gear reducer with the proper lubrication from the table below depending on the operating environment of the sootblower. For some applications it is necessary to mount the sootblower with the gear reducer above the motor. In this situation grease should be used in the gear reducer to restrict leakage. It is recommended that the oif should be replaced every 18 months.

Ambient Operating Recommended Recommended
Temperature Oil Grease
Above 32°F (O°C) Mobil SHC 630/634 Mobilith SHC 007
Mobil DTE BB
OOF to 32°F (-18°C to O°C) MoblJ SHC 630/626 Mobilith SHe 007
Mobil Synthetic 10W-40
Below OaF (-18°C) Mobil SHe 626 Not Recommended
Mobil Synthetic 10W-40 The gear reducer should be half filled with approximately ~ pint (.25 liter) of oil or grease. Lubricant can be added to the gear reducer through any of the plugs on the gear reducer depending on it's orientation. One of the plugs is cross drilled for venting the gear cavity and is installed for upright operating position. If the sootblower is installed in a position that allows the lubricant to leak out of the vent it should be switched with one of the other plugs for venting.


Section 6

Preventative Maintenance

These instructions and schedules serve as an initial guide until the plant/customer determines a plan more effective to its own specific operating conditions. The recommended maintenance schedule provided in this section is aggressive and won't be completely necessary with new equipment but as it ages this schedule will ensure the sootblowers stays in best condition for reliable service.

6.1 RECOMMENDED MAINTENANCE FOLLOWING FIRST MONTH OF SERVICE

1. Check the blowing pressure at the valve.

2. Check the valve operation and the blowing pattern.

3. Check limit switch operation at completion of cycle.

4. Lubricate front bearing.

5. Ensure air relief valve operates properly to vent the valve, screw tube and nozzle.

6.2 SIX MONTHS SERVICE (OR 500 CYCLES)

1. Check sootblower operation.

6.3 18 MONTH SERVICE

1. Check sootblower operation.

2. Check feed tube packing, add rings or replace as needed.

3. Check condition of feed tube.

4. Check drive pins in main drive gear.

5. Check condition of cam and trigger.

6. Change oil in motor gear reducer.

7. Inspectthe inside of the remote mounted control box.

8. During outage check the nozzle, cleaning pattern and boiler tube condition inside boiler.

6.4 36 MONTH SERVICE

1. Remove sootblower from service and completely clean all components.

2. Check condition of feed tube and replace packing.

3. Check condition of screw tube and nozzle assembly.

4. Replace drive pins in main drive gear.

5. Replace drive shaft bushing on the front bracket.

6. Replace front bearing.

7. Change oil in motor gear reducer. B. Replace drive key on motor shaft.

9. Replace valve stem packing on poppet valve.

10. Check condition of valve stem disc and seat.

11. Check condition of electrical cables and connections.


6-1

""""~~"'~,~''' •• _ ..... ,. __ ._, ••• _"_,.",_'" .. ;.:. .... _ .. _~,, __ .:_ .. ,,'_, ,'-.~._.~., •• _, .. ~.:' __ ;_. __ , .. _:. __ .. o __ , .. ,· ...... _·.c .. ",,;._ ..... , .. __ .•• _._ ..... __ •• _.

Section 7 Troubleshooting

Sootblower fails to start:

• Check that the motor power disconnect switch (or circuit breaker) is closed (on).

• Ensure all plugs and wires are connected and tight.

• Verify the motor power source is energized.

• Check if sootblower has overload alarm and if overload protection is operating properly.

• Ensure there is control power in the control box.

• Check if timing relay contact not closed.

• Check that all sootblowing permissives are met at the control system.

• Verify proper operation of the rear limit switch and sootblower is in rest position.

• Verify that the starter actuates when a start is initiated.

• Try to start the sootblower locally.

Motor overload alarms is on/higher motor amps than usual:

• Check that nothing is binding in the gear drive.

• Wall opening may be slagged over not allowing the nozzle to penetrate.

• Check that the feed tube packing is not too tight.

• Check screw tube alignment with front bracket and drive pins.

• Check that the seal plate in the wallbox is adjusted properly.

• If the sootblower's starter is equipped with overloads, check the status of the overload and verify that the current setting matches the motor rating. If the central sootblowing control system performs the current measurements, check system for "Motor Stalled" alarms. If present, check the motor and interconnecting wiring before resetting.

Motor runs but sootblower does not start:

• Check the drive key on motor shaft and gear reducer shaft.

• Check pins in drive shaft coupling and drive pinion.

Motor does not reverse at end of blowing revolutions:

• Check timer relay.

• Reverse relay coil maybe burned out.

• Overload contact maybe open.

• Rear limit switch contact maybe held open.

Motor reverses but sootblower does not retract:

• Check front pawl on guide bar and cam engagement.

• Check drive assembly, pins and keys.

Drive pins and keys are sheared:

• Check for nozzle binding in wallbox or wall tubes.

• Check cam, trigger and guide bar engagement.

• Check for excessive pipe loads or expansions causing misalignment.

Steam/air leaking from poppet valve:

• Check valve stem packing. Tighten or replace packing as needed.

• Check that feed tube is properly attached,

• Check feed tube gasket. Replace gasket if needed.

• Check the connection between the poppet valve and companion flange. Replace the gasket if necessary and torque to 175 ft-Ibs ± 25 ft-Ibs (237 N-m ± 34 N-m).


7-1

Section 7

Troubleshooting

Steam leaking through poppet valve in closed position:

• Leakage can be detected by a hissing sound in the poppet valve or a warm feed tube when

the sootblower has not operated recently.

• Check that linkage is not binding and can jiggle freely.

• Check that valve stem packing is properly tightened.

• Check valve stem condition and alignment.

• Remove valve and inspect for foreign matter lodged between seat and valve body.

• Inspect for steam cut or worn seat. Replace with new seat as necessary.

Poppet valve fails to open/little or no cleaning:

• Ensure the poppet valve pressure control disc has been properly set.

• Check the poppet valve trigger and cam operation.

• Check for interference that might obstruct valve operation.

• Check that the valve stem packing is not too tight and the stem is not bent.

Blowing pressure fluctuation:

• Ensure header pressure is maintaining proper setting at the pressure reducing station.

• Inspect nozzle for failure.

• Monitor poppet valve pressure.

Wall tubes appear damaged:

• Check blowing pressure.

• Decrease cleaning revolutions if initially set for more than one revolution.

• Check nozzle setting and cleaning path.

• Check for excessive condensate in steam supply.

Screw tube or feed tube internal corrosion:

• Check that air relief valve is operating properly to purge boiler gases. Air should be drawn in (negative pressure boiler) or forced (positive pressure boiler).

• Check that the condensation drain control is functioning properly.


7-2

r

I

Section 8 Storage

8.1 GENERAL INFORMATION

Sootblowers should be stored upon receipt in a dry building where temperature and humidity conditions are controlled to best preserve the working order of the sootblower. Under these conditions, the equipment may be stored for an extended period of time requiring periodic visual inspections.

In the event it is not possible to store the sootblower under the conditions outlined above, it must be realized that the equipment will be adversely affected by prolonged storage. To reduce the adverse impact on the equipment, the sootblower should be stored in at least a simple, temporary frame structure with roofing of heavy-duty waterproof material. The site should be a firm, level and welldrained area with waterproof material placed so that moisture will not be absorbed under the equipment. The frame structure should be of sufficient length and width to overhang the sootblower to avoid wind blown precipitation from reaching the stored equipment, The structure should be open at both ends to the prevailing wind so fresh air may circulate throughout the enclosure.

8.2 STACKING SOOTBLOWERS FOR STORAGE

Remove the bottom condensate drain plugs from all motors to prevent condensate buildup and ultimate corrosion of the motor.

I

All equipment should be stored upright. IR-3Z sootblowers are shipped in cardboard boxes, these should be supported underneath to keep boxes off the ground. The sootblowers should be stacked no higher than two rows.

8.3 SOOTBLOWER PRESERVATION

If the sootblower is to be stored for more than six months, the motor gear reducer should be filled 100 percent with either the proper lubricant or a light weight motor oil to protect the gear drive from corrosion. When the sootblower is placed into operation, the oil should be drained and refilled to the operating level with the proper oil.

Diamond Power cannot be held responsible for damage to equipment resulting from improper site handling, site storage or storage maintenance. Furthermore, because of the many variables involved in storage of equipment, there is always the possibility of some damage in storage, particularly to electrical equipment. Once the shipment of the equipment has been accepted, damage resulting from storage is the responsibility of the customer. The-best way to minimize this possible damage is to follow these instructions.

8.4 ELECTRICAL EQUIPMENT STORAGE

All electrical box openings are sealed with plugs or tape prior to being shipped. All electrical boxes should have desiccant bags. These provisions should be maintained throughout storage to help prevent moisture from entering the enclosures.

8.5 DIAMOND POWER LIABILITY


8-1

1

1 1

I r

;

.~ ~ j

i

Section 8

Storage

Checklist for initial sootblower storage:

1. Remove condensate drain plugs from bottom of motors if applicable.

2. Fill motor gear reducer with oil if to be stored more than six months.

3. Stack sootblower off ground and protected from weather.

4. Add desiccant bags to electrical enclosures. Protect electrical enclosures from weather.

Six month storage inspection:

1. Ensure boxes are not damaged and are protected from weather.

2. Replace desiccant bags inside electrical enclosures.


8-2

Section 9

Part Identification Forms

The following attached figures show all the components for the IR-3Z sootblower, including how they are assembled and part numbers for replacement parts. These forms may include parts and configurations not applicable to your specific installation, if you have questions please contact your local Diamond Power representative.

PI Form Description
Number
PI-3312 Procedure for Installing Flexible Seat and Disc into Poppet Valve
PI-380B Positive Pressure Wallbox
PI-4338 IR-3Z Sootblower Assembly
PI-4339 IR-3Z Gooseneck Valve Assembly
PI-4340 IR-3Z Drive Unit Assembly
PI-4341 IR-3Z Electric Control Assembly
PI-4342 IR-3Z Guide Bar & Support Plate Assembly
PI-4343 IR-3Z Front Bracket Assembly
PI-4344 IR-3Z Screw Tube & Packing Assembly
PI-4345 IR-3Z Nozzle Assembly
PI-5074 Negative Pressure Wallbox IM-15035 December 2004

9-1

----_-_._----_

PROCEDURE FOR INSTALLING FLEXIBLE SEAT AND DISC INTO SERIES 600 & 900 POPPET VALVES

1. WHEN THE EXISTING VALVE SEAT IS IIELDED TO THE BODY, IT IIILL BE NECESSARY TO REMOVE THE OLD WELD MATERIAL FROM THE BODY AND ALLOW SUFFICIENT CLEARANCE FOR INSTALLING THE NEW SEAT. CAUTION SHOULD BE TAKEN tlUI TO REMOVE MATERIAL FROM THE FACE OF THE SHOULDER UNDER THE SEAT, THIS SHOULDER POSITIONS THE NEW SEAT TO THE CORRECT DEPTH IN THE BODY.

2, ASSEMBLE AND POSITION THE SEAT INTO THE BODY BY USE OF THE SEAT PROTECTOR WHICH PROTECTS THE SEAT AND LOCATES IT IN RELATION TO THE VpLVE STEM GUIDE. TIGHTEN THE LOCKNUT FINGER-TIGHT TO HOLD DOliN THE SEAT DURING WELDING. REFER TO FlGURE A.

A. TOOLS REQUIRED FOR IIELDING,

< 1) SEAT PROTECTOR - SERIES 600 VALVE (DPSC PIN 310925-1029) SERIES 900 VALVE (DPSC PIN 310925-2027) (2) D. C. WELDING EQUIPMENT

(~) SET AT 82-92 AMPERES

(b) REVERSE POLARITY

(3) RECOMMENDED IIELDING ROD IS ANY ROD CONFORMING TO AIIS-A5 5 CLASS [7015 OR E7018. (E70l8 ROD MAY BE OBTAINED FROM DIAMOND POIIER UNDER PIN 907947-0003)

USE A MAXIMUM OF Tlio 3/32 DIA. RODS PER SEAT.

B. IIELDING PROCEDURES'

(1) HOLD ROD APPROXIMATELY 85' TO DEPOSIT MORE METAL ON THE SEAT THAN ON THE BODY.

(2) START WELD 90' FROM POINT OF LEAST CLEARANCE BETWEEN BODY AND SEAT. MAKE SINGLE PASS WELD ONLY, WITH NO INITIAL TACKING APPLIED. PROCEED TOWARD POINT OF LEAST CLEARANCE.

(~) OVERLAP 1/2' TO 3/4' BETWEEN ROD APPLICATIONS

(b) CLEAN SLAG FROM WELDED AREA BETWEEN ROD APPLICATIONS

(c) UPON COMPLETION OF THE WELDING, SLAG MUST BE CHIPPED FROM WELD AND THE VALVE BODY SHOULD BE WIRE BRUSHED. CARE SHOULD BE TAKEN TO INSURE PROTECTION OF THE SEALING SURFACES.

3. THE VALVE SEAT SHOULD BE LAPPED FOLLOWING THE WELD PROCEDURE TO ASSURE FLAT SEAT SURFACES.

A. TOOLS REQUIRED FOR LAPPING,

(1) ROUGH LAPPING DISC - SERIES 600 VALVE (DPSC PIN 313641-1125> SERIES 900 VALVE (DPSC PIN 314718-1121) (2) FINISH LAPPING DISC - SERIES 600 VALVE (DPSC PIN 313641-2123) SERIES 900 VALVE (DPSC PIN 314718-2129)

en) ONE DISC IS SERRATED FOR ROUGH LAPPING AND THE OTHER DISC FOR FINISH LAPPING & BURNISHING.

NOTE' ALL SURFACES OF DISCS MUST BE KEPT LAPPED FLAT. LAPPING MACHINE OR SURFACE PLATE CAN BE USED TO MAINTAIN THE DISC SURFACE.

(3) LAPP I NG COMPOUNDS,

(~) CLOVER'S' COMPOUND, CLOVER MANUFACTURING COMPANY (DPSC PIN 902530-0001) (b) 305A COMPOUND, U. S. PRODUCTS COMPANY (DPSC PIN 902530-0002)

(c) GREEN ROUGE, U, S. PRODUCTS COMPANY (DPSC PIN 902530-0003)

THROAT BORE

FINISH LAPPING DISC (PLA IN)

VALVE SEAT

ROUGH LAPPING DISC ( SERRATED>

STEM GUIDE

SEAT PROTECTOR ASSEMBLY

VALVE BODY

LOCKNUT

FIGURE A

L- ~ __

PROCEDURE FOR INSTALLING FLEXIBLE SEAT & DISC INTO POPPET VALVE

P I FORM: 3312 SHEET 1 OCTOBER 2003

~----~~~---------"------"""--------.--.' ... -.---"- --- ...... __ ..... __ ...... ,,---- _ ..... _._ .. __ ...... _.----_ .. _--_._--_._---_" ....

(4) LAPPING EQUIPMENT OPTTON~

(0.) WOBBLE STICK & DISC (SEE FIGURE 'B' FOR DETAILS) (b) MANUAL OPERATED VALVE GRINDER & DISC

(c) SMALL CAPACITY AIR MOTOR WITH FLEXIBLE SHAF~ & DISC

(5) INSPECTION EQUIPI4ENT,

(0.) BLUE BLOCK - USED FOR CHECKING FLATNES~ AN UNUSED LAPPING DISC WHICH IS ABSOLUTELY FLAT CAN ALSO BE USED FOR THIS PROCEDURE

(b) pRuSSIAN BLUE - USED TO DETERMINE HIGH & LOW MARKINGS. REFER TO INSPECTiON PROCEDURE BELO~

B. LAPP J NG PROCEDURE,

(1) ROUGH LAPPING (USE SERRATED DISC)

(0.) CHARGE FRESH LAPPING DISC WITH CLOVER 'B' COMPOUND

(b) LAP FOR TWO FIVE-MINUTE CYCLES, CHECKING SURFACE AT END OF EACH CYCLE.

(2) FINISH LAPPING (USE PLAIN DISC)

(0.) CHARGE FRESH LAPPING DISC WITH NUMBER 30SA COMPOUND

(b) LAP FOR TWO FIVE-MINUTE CYCLES, CHECKING SURFACE AT END OF E(>.CH CYCLE.

(3) BURNISHING (USE PLAIN OISC)

(0.) CHARGE LAPPING DISC WITH GREEN ROUGE (b) LAP FOR FIVE MINUTES

(4) INSPECTION PROCEDURE

(0.) COVER SURFACE OF BLUE BLOCK WITH A VERY THIN UNIFORM COATING OF PRUSSIAN BLU~

(b) PLACE BLUE BLOCK CAREFULLY ON LAPPED SEAT. APPLY FINGER PRESSURE AND MOVE BLUE BLOCK BACK AND FORTH SLIGHTLY. CAREFULLY REMOVE BLUE BLOCK.

(c) INSPECT LAPPED SEAT.. IF DYE TRANSFER IS UNIFORM, THEN SEAT IS SATISFACTORY. IF DYE TRANSFER IS NOT UNIFORM, THEN SEAT IS NOT FLAT AND THE COMPLETE LAPPING PROCEDURE MUST BE REPEATED.

4. AFTER THE LAPPING PROCEOURE IS COMPLETED, THE VALVE BODIES ARE TO BE CLEANED WITH A SMALL BRISTLE BRUSH USING CLEAN SOLVENT. DRY WITH AIR OR SPECIAL WIPING TOWEL~ SPECIAL CARE SHOULD BE GIVEN TO REMOVE ALL MINUTE FORE! GN PART I CLES.

A. ASSEMBLY PROCEDURE,

(1) INSTALL VALVE DISC AND STEM ASSEMBLY INTO VALVE BODY WITH BODY RESTING ON ITS SIDE. MAKE SURE OF CLEANLINESS PRIOR TO AND DURING THE COMPLETE INSTALLATION.

(2) ASSEMBLE PACKING AND VALVE PACKING NUT. BOTH ARE TO BE OIL FREE.

(3) PLACE VALVE BODY IN THE UPRIGHT POSITION, KEEPING POSITIVE CONTACT AT ALL TIMES BETWEEN THE SEAT AND DISC.

(0.) INSTALL VALVE SPRING, RETAINER AND YOK~ MAINTAIN POSITIVE SPRING TENSION ON THE DISC STEM AT ALL TIMES.

(b) IF VALVE BODY IS NOT IMMEDIATELY PUT INTO SERVICE .. ALL OPENINGS SHOULD BE COVERED TO PROTECT THE INTERNALS DURING STORAGE.

7/16' R

~' 11/16' KNURL

!D'--------------~

FIGURE B

~- ond Power PROCEDURE FOR INSTALLING

~ Machine (ftub61J Co. Inc. FLEX I BLE SEA T ex DISC INTO "D~P" ... d_""'.L'lc._ POPPET VALVE

PI FORM: 3312 SHEET 2 OCTOBER 2003

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