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PO SC10116

No. SC10126
SC10127
SC1128
No. SC10116 TSO SM
Ver. REV 0
Date 2011.10
Des.
Ck.
App.

INSTRUCTIONS
for
INSTALLATION
OPERATION
MAINTENANCE
NON-COOLING THERMOPROBE
TS-O

Shanghai CLYDE BERGEMANN Machinery Co., Ltd.


Tel: 86-21 65396385
Fax: 86-21 65661886
E-mail: clydek@online.sh.cn
Non-Cooling Thermoprobe
TS-O

These operating instructions were prepared to the best knowledge in order to inform
our customers. They are the result of our practical experiences.

These instructions must be observed in order to mount and operate the thermoprobe
without any problems or dangers and also in order to maintain possible warranty
claims.

All technical data is subject to change without notice.

For planning, use, operation and maintenance of thermoprobe, not only these
operating instructions but also the corresponding regulations for the prevention of
accidents as well as the corresponding standards must be observed.

We recommend having repair and maintenance work carried out by SHANGHAI


CLYDE BERGEMANN expert personnel.

If you have any questions, please call our service department.

Tel.: (021)65396385

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General Safety Notes

Transport
  Individual machines or machine parts shall be transported by means of the main
lifting facilities provided for this purpose, such as lifting lugs. Packaged parts
should be transported in the original packing by means of appropriate means of
transportation.

  Lifting gears and means of transportation shall be used in accordance with the
machine weight in question.

  Transport of the machines and machine parts shall take place very carefully in
order to avoid damage.

Installation
  The machine or machine parts shall only be installed at the places provided for
these according to the installation drawings and installation instructions. Cabling
shall be carried out in line with the cabling diagrams.

  Installation and cabling shall be carried out according to the rules of the art and
must only be performed by duly qualified and authorized personnel.

  In the event of failure to comply with the rules of the art of installation and
cabling, the machine can give rise to personal injuries and material damage.

Operation and maintenance of the facility


  The facility shall only put into operation, be operated and serviced by duly
trained and qualified personnel since improper operation and maintenance may
cause risks for limb and life of the user or third parties as well as affect the
facility and further assets.

  The owner shall ensure that the operating and maintenance personnel are
thoroughly familiarized with all safety and warning requirements and that these
requirements are fulfilled.

  Before commissioning the operating instructions and safety remarks shall be


read and observed. The specialists must familiarize themselves with all
components and actuation elements of the facility and with the function of the
facility..

  During operation of the facility it is forbidden to enter the dangerous area.


  Repair and maintenance work shall only be performed in the de-energized and
pressureless condition.

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 Safety of the facility can be affected if replacement and wear parts other than those
provided by the manufacturer are used and the scheduled maintenance intervals are
not observed.

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the following "Technical Characteristics":

Wallbox:  Negative   Positive

Support Probe Tube:  without   with

Transmitter:   without  with

Electrical Installation: .   Standard  Local control box

Sealing air piping:   with  without

Sealing air piping with fan:   with  without

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CONTENTS

Part A Description and Design Data

Section A1 Description of the Thermo probe


Section A2 Data Sheets

Part B Installation and Commissioning

Section B1 Thermo Probe Installation


Section B2 Commissioning

Part C Thermo probe Operation

Section C1 Operation
Section C2 Troubles with Thermo Probe

Part D Maintenance and Servicing

Section D1 Thermo Probe Maintenance


Section D2 Servicing of the Thermo Probe

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Part A Description and design data

Section A 1 Description of the Thermo probe

1. Principle and Design


2. Track Beam
3. Thermo Probe Carriage
4. Measuring Device and Probe Tube
5. Drive and Control
6. Transmitter
7. Wall Box
8. Suspension
9. Sketches

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1. Principle and design


Reference: Sketch A 1-05

The Thermo probe is designed for positioning a thermo couple element in the
flue gas stream. It is an accurate and dependable device for monitoring flue gas
temperatures.

The thermo probe is usually used in critical zones of the boiler superheater /
reheater inlets to prevent tube metal overheating during boiler start up.

The thermo couple is mounted on the front end of the probe tube, which
transverses into and out of the flue gas stream.

During boiler start-up, the probe tube advances into the flue gas pass until the
thermo couple attains the central area, where it remains. The temperature of this
zone is measured.

For measuring the flue gas temperature in the area between the boiler centre
and the side wall, the control circuit of the thermo probe is designed in such a
way that the probe tube can be stopped at each desired point of its travel. A
position transmitter indicates the respective distance of the thermo couple tip to
the boiler wall.

2. Track beam
Reference: Sketch A1-05
Sketch A1-07

The track beam essentially consists of a double T-beam used for guidance of the
probe carriage. A toothed rack which is engaged in the drive pinion of the probe
carriage is arranged below the double T-beam. The probe tube guide is located
at the front end of the track beam in order to support and guide the probe tube.

A bracket used to fasten the probe at the boiler is arranged at the front plate. A
second suspension point is located at the rear end of the track beam.

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3. Probe Carriage
Reference: Sketch A1-06
Sketch A1-08

The probe carriage consists of a casing to which the geared motor and rollers
are fastened.

The spur worm gear driven by the three-phase motor is equipped with an output
shaft. The drive pinion engaged in the toothed rack of the track beam which
moves the probe carriage axially, is arranged on this output shaft.

4. Measuring Device and Probe Tube


Reference: Sketch A1-05

The probe tube is made of creep-resistant steel. It is arranged with its rear end in
the probe carriage and the front part is placed in the probe tube guide. The
probe head is a protective shield of creep-resistant material with slotted holes to
permit the flue gas to flow freely around the thermo couple tip. The thermo
couple tip is thus protected from damage.

The thermo couple element is centrically guided through the probe tube to a
junction socket at the rear end. It is insulated and enclosed in a creep-resistant
steel tubing.

The junction socket adapts the junction plug of the lead wire which brings the
signal from this point to the stationary connection box (comparison point) fixed
on the track beam. The instrument wiring is guided to this stationary connection
box.
5. Drive and Control
Reference: Sketch A1-05
Sketch A1-09

Power and control voltage are supplied to the probe through local control box.
The limit switches used to control the forward and reverse movement of the
probe carriage are connected to the local control box through the control line.

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6. Transmitter
Reference: Sketch A1-05
Sketch A1-09

The probe is provided with a transmitter together with a voltage supply unit for
position indicating, showing the distance of the thermo couple tip to the boiler
wall. The voltage supply unit can be connected with an indicating instrument.

7 Wall Box (Negative Pressure)


The wallbox with sliding plate seals the probe tube penetration through the boiler
wall. The sliding plate adjusts itself to the movements of the probe tube which
are caused by its deflection and by the thermal expansion of the boiler wall.

With permanent negative flue gas pressure, the opening in the sealing air
connecting nozzle provides for sufficient sealing air in direction to the boiler.

For short time positive flue gas pressure, sealing air can be provided for at the
connecting nozzle.

If a positive pressure on the flue gas side prevails, a special positive pressure
wallbox must be used.
.
8. Suspension
Reference: Sketch A 1-11

By means of the front suspension, the probe is fastened to the suspension


console which is installed at the boiler wall. The rear probe suspension must be
mounted to the suspension to be provided for by customer.

The suspensions are designed in such a way that the horizontal and vertical
expansion of the boiler wall can be taken up.

These expansions must also be considered when designing the probe


suspensions by customer.

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9. Sketches

1. Sketch A 1-05 Thermo Probe


2. Sketch A 1-06 Drive system
3. Sketch A 1-07 Probe tube guide
4. Sketch A 1-08 Probe carriage
5. Sketch A 1-09 Power supply
6. Sketch A 1-10 Wallbox
7. Sketch A 1-11 Suspension of the probe

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Sketch A1-05

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Sketch A1-06

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Sketch A1-07

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Sketch A1-08

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Sketch A1-09

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Sketch A1-10

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Note: where erection, the offset values shall be according to the information attached in the GA
drawing.(Section B1, Part 9 Installation Documents)

Sketch A1-11

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Section A 2 Data sheets

1. Technical data
2. Motor data (drive motor)

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Technical Data
1.General Data
Blower Type TS-O
Unit 4
No. of thermo probe 2
2.Drive
Power Per Blower kW 0.55
Travel Speed m/min 1.44
Frequency Hz 50
Travel mm 7965
Operational Time s 554
3.Dimensin and Material
3.1Thermocouple
Model WRNK2-372
Element Type K
Outer Diameter mm ∅6
Material Ni/Cr-Ni/Si
3.2 Thermo Tube
Outer Diameter mm ∅89
Material T91
3.3 Tube Tip
Outer Diameter Mm ∅89
Material 1Cr18Ni9Ti
4.Wallbox Negative
5. Fan Without

Notes:
The operation times are based on a tolerance of ±10%.

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Motor Data

Item Blower Type: TS-O


1 Type of Motor M2QA80M4A
2 Maker of Motor Shanghai ABB
3 Quantity Per Boiler 2
4 Power kW 0.55
5 Speed 1/min 1400
6 Power factor Cos phi 0.68
7 Efficiency η % 72.5
8 Rated Current A 1.55
9 Rated Torque Nm 3.56
10 Weight kg 16
11 Voltage V 415
12 Frequency Hz 50
13 No. of phases 3
14 Insulation Class F
15 Enclosure IP 55
16 Rotor Design &Duty Cage Rotor , Continuous
17 Mounting Flange
18 Cooling method TEFC

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Part B Installation and Commissioning

Section B 1 Thermo Probe Installation

1. Transport and Storage


2. Arrangement of the Thermo Probe
3. Suspension Bracket and Wallbox
4. Lifting Instruction
5. Front Suspension
6. Rear Suspension
7. Electrical Installation
8. Assembly Check
9. Installation Document

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Attention!
These works must be carried out only by qualified personnel.

Any deviation from the instructions contained in this manual will render any
guarantees null and void!

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1. Transport and storage


Transport of the probes with accessories is to be carried out very carefully to avoid
damage. The suspension points provided at the probes are to be used for
transport (refer to sketch B1-03).

In case an intermediate storage for a longer period of time should become


necessary, the probes are to be stored in a heated room in order to protect the
electric drive and control equipment against moisture and idle corrosion.

In cases of doubt and extreme climatic conditions Clyde Bergemann has to be


informed.

Attention:

All bright parts (i.e. bolts, joining elements etc.) must be protected against
corrosion (e.g.: rub with grease).

2. Arrangement of the Thermo Probe

The thermo probes and the accessories are marked with name plates indicating
the installation point at the boiler. Attention is to be paid that the number of the
installation point at the boiler corresponds to that of the probes, since in many
cases different types of probes are available.

3. Suspension Bracket and Wallbox


The suspension brackets with screwed-on wallbox are to be mounted to the crimp
box of the boiler wall and aligned. It is important that the bore holes for the hinge
bolt are to be exactly horizontal in order to avoid an inclined position of the probe.
4. Lift Instruction
Reference: Sketch B 1-03

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Sketch B1-03

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5. Front Suspension

The probe is to be lifted to a mounting height by means of a hoist and must be


provisionally held at this height.

The probe head is to be inserted in the wall box and the front suspension must be
placed at the support roller.

6. Rear Suspension

The rear suspension of the probe must be installed at the scaffold or the like in
such a way that the mounting position of the probe can be exactly kept in all three
axes (axial, vertical and horizontal).

By means of a hoist, the probe must be lifted so that the threaded rods can be
inserted into the suspension bores of the scaffold and can be secured.

The threaded rods must be displaced laterally and in probe axis direction so that
the probe is placed in the prescribed angle to the boiler wall.

The final height of the probe must be adjusted by means of the threaded rods.
(refer to sketch A1-11)

The installation documents (Part 9) must be carefully observed.

Where erection the offset values shall be according to the information attached in
the GA drawing (refer to Part 9).

After alignment, the threaded rods must be fixed by means of a lock nut.

7. Electrical Installation

All internal wiring of the probe has already been carried out in the workshop. At the
building site the power and control cables are to be laid and connected up to the
terminal box or plug at the track beam of the probe.

Laying of cables is to be carried out in accordance with the binding terminal


connection and cabling plans which also contain the line cross sections.

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8. Assembly check

After assembly of the probe the following details are to be checked for compliance
with the installation documents:

Check the place of installation.

Since the fixed point is located at the front probe suspension, i.e. at the boiler, the
probe moves together with the boiler wall.

The vertical thermal expansion of the boiler wall is to be taken into account by
appropriate inclined position of the probe tube in cold condition of the boiler
(mounting position). When the boiler is hot the probe tube shall be installed
horizontally.

At the rear end position (idle position) of the probe carriage the distance of the
probe head from the internal boiler wall must be in accordance with the regulations.
Also the distance between probe head and boiler wall at fully projected probe must
be in compliance with the prescribed dimension. In case of deviations contact
CLYDE BERGEMANN.

In all operating conditions it must be possible that the probe tube can be moved
easily in axial and radial direction inside the sealing elements (lamella).

It has to be checked whether possibly available the sealing air has connected.

9. Installation Documents

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Section B 2 Commissioning of the Thermo probe

1. Work before Start-Up


2. Commissioning of the Probe

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Attention!
These works must be carried out only by qualified personnel.

Any deviation from the instructions contained in this manual will render any guarantees null and
void!

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1. Work before Start-up


1. Prior to commissioning the probe is to be cleaned of dust and dirt. All locked parts (e.g.
transport securing devices and angle brackets) are to be removed.
2. The probe is to be carefully checked for damage which might be caused during
transport or assembly. Missing and damaged parts are to be replaced. Checking of
electrical parts is very important.
3. In the workshop the spur worm gear is filled with lubricant. The residual lubrication
work is to be carried out in accordance with the maintenance schedule (chapter D1).
Attention: all bright parts (i.e. bolts, joining elements etc.) must be protected against
corrosion (e.g.: rub with grease).
4. The centrical position of the probe tube in the wall box is to be checked. It has to be
ensured that the sealing elements (sliding plate or lamella) are easily moveable.
5. The arrangement of the probe head in the rear end position and at measuring start is
to be checked. The installation documents are to be observed.
6. Check whether the probe has been wired in accordance with the binding terminal
connection and cabling plans.

2. Commissioning of the Probe


The first commissioning is to be carried out as follows:
1. The drive motor is to be isolated from power supply. The probe carriage is to be
moved forward about 0.3m by means of the hand crank or the pneumatic screws; the
screws are to be slipped on to the rear shaft end of the drive motor.
2. In order to check the direction of rotation of the motor the voltage supply is to be
switched on and immediately switched off again, and the direction of movement of
the probe carriage is to be observed at the same time. When the carriage has moved
backwards, the direction of rotation is correct. Otherwise 2 motor lines at the motor
terminal box are to be exchanged.
3. In order to check the function of the rear limit switch, the probe carriage is to be
about 0.3m before the rear end position. When the electric control is switched on, the
probe carriage immediately reverses in accordance with (2). If not, the voltage supply
has to be interrupted and the control is to be checked. When the rear limit switch is

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now operated manually, the probe carriage has to come to a stop. When the limit
switch is released, the probe carriage finally moves back to the rear end position.
4. When the front limit switch is checked, the probe carriage is to be in rear end position.
When the manual start-push button in the switchboard is pressed, the carriage will
move forward. After a short travel, the front limit switch is to be pressed manually for
a few seconds. Then the probe carriage must reverse and move back to its left end
position. In case the carriage does not reverse, the voltage supply is to be
interrupted immediately and the control is to be checked.
5. In case of a plant equipped with sequence control, the entire plant shall be run
through automatically after all probes have been individually checked. For further
details refer to the description of the electric control.

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Part C Thermo probe Operation

Section C1 Operation and Operation Data

1. Operation
2. Operating at longer Standstill Period
of the Thermo Probe

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Attention!

Any deviation from the instructions contained in this manual will render any
guarantees null and void!

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1. Operation of the Thermoprobe


The control of the thermoprobe adopt centralized control .This control brings into Control
of sootblower system, There is a local control box
on the thermoprobe body.
The user can operation of the thermoprobe can be done by means of a remote control box
and / or local control box. Details are to be taken from the detailed “Description of the
Electrical Control System”.

2. Operation at longer standstill period of the Thermoprobe


Normally the probes shall be operated so many times that their operational capability is
ensured at any time.
But if they are operated not at all or only in rare cases, they should at least be operated
every 14 days to make sure that all moveable parts, particularly the limit switches, remain
operative.

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Section C 2 Thermo probe Troubles

1. Troubles in the Movement


2. Measures when Overrunning Limit Switches
2.1 Rear Limit Switch
2.2 Front Limit Switch

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Attention!
These works must be carried out only by qualified personnel.

Any deviation from the instructions contained in this manual will render any
guarantees null and void!

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1. Troubles in the movement


7. When the movement of the probe is disturbed by sluggishness the overload relay of
the probe control shall respond and change over the direction of rotation of the drive
motor. In this manner the reverse movement of the probe carriage shall be initiated.
The rear limit switch switches the motor off when the idle position is reached.
8. When the pressure in the probe network drops below the prescribed minimum value, a
pressure monitoring shall effect the immediate return of the operating probe to its initial
position.
9. If during a trouble the probe drive fails during the measuring process, the probe
carriage is to be moved back by means of the hand crank which is to be slipped onto
the rear shaft end of the motor. Ensure that the drive motor is disconnected and cannot
start again. The use of a hoist or a similar device for moving the probe carriage back is
not allowed because the gear might be damaged.

2.Measures when Overrunning the Limit Switches


If the limit switch is overrun, the driving pinion of the probe carriage runs off the toothed
rack in order to avoid further damage. By this means, the axial movement of the probe
carriage is interrupted.
In order to make the probe ready for work again, proceed as follows:

2.1 Rear Limit Switch


1. The motor must be switched off. It must be guaranteed that it cannot start again.
2. The probe carriage must be moved so far to the front that the driving pinion contacts
the toothed rack.
3. By actuating the crank handle which must be slipped onto the rear shaft end of the
driving motor, the driving pinion engages when the probe carriage is powerfully
pressed at the same time.
4. The probe carriage is again located in final position, the limit switches must be
checked for damages and the probe control must be checked for faults.
5. After repairing the damage, proceed as detailed in Section B 2.

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2.2 Front limit switch
1. The motor is to be disconnected when the probe carriage can be moved back.
Ensure that the motor cannot start again.
2. In order to initiate the reverse movement, the probe carriage is to be manually
pulled back if -necessary by means of a hoist or similar device – until the pinion is
in contact with the toothed rack.
3. Now the probe carriage is to be moved back about 300 mm by means of the hand
crank so that it exceeds the front end position and is within the normal operating
range. In this case attention is to be paid that the switch lever of the limit switch is
not jammed on the stop rail of the probe carriage.
4. Try to reverse the probe carriage by means of a motor and electric control. When
the motor is switched on pay attention that the direction of travel is correct.
5. As soon as the probe carriage is back in its idle position, check the limit switches
for damage and the control of the probe for defects.
6. After removal of the damage the probe can be put into operation again.

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Part D Maintenance and Servicing

Section D1 Maintenance of the Thermo Probe


1. Maintenance Schedule
Lubricant List
2. Track Beam
2.1 Track Beam Rail
2.2 Toothed Rack
2.3 Probe Tube Guide
3. Probe Carriage
3.1 Spur Worm Gear and Motor
3.2 Case Bearing
4. Probe Tube and Probe Head
4.1 Lance Tube
4.2 Feed Tube
5. Power Supply System
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Attention!
These works must be carried out only by qualified personnel.

Any deviation from the instructions contained in this manual will render any
guarantees null and void!

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1. Maintenance Schedule

Item Description Service interval:


Type of routine servicing:
2. Track beam
2.1 Track beam rail according to the dust built up blow with
compressed air
2.2 Toothed rack according to lubrication list
2.3 Probe tube guide according to sheet
3. Probe carriage
3.1 Spur worm gear and motor according to lubrication list
3.2 Rollers and supporting rollers no servicing required
4. Probe tube and Probe head at boiler shut down
check for damages due to corrosion,
thermal shocks and scaling
5. Power supply system no servicing required

Remarks:
Above mentioned service times are basing on an 8-hours operating interval. In case of
alteration, adapt service time accordingly. The content of this sheet is advisory. Any
liabilities or claims cannot be derived from this sheet.

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LUBRICATION LIST FOR TS.. D1-03


Oil
Item Lubricating Lubricant Lubricating Quantity Remark
Viscosity Viscosity Flash point Pour Density
point interval per
name
class 40°C °C Point at 20°C filling
°C (g/cm3)
1 Gear box Synthetic
680 612~748 >=180 <=-5 - 3 Years 1.55L
worm oil 680
2 Motor bearing Maintenance free
3 Rack TECTYL - Gear wheel
(25°C) >40 - 0.87 1x per year 0.5L
506EH spray
800±300
GREASE
Item Lubricating Lubricant Lubricating Quantity Remark
Consistency Dropping Application
point interval per
name
class point °C range °C filling

Note:
1. Above mentioned lubricating intervals are based on 8 hours blowing cycle. In case of alternation it has to be adjusted accordingly.
2. The content of this sheet is purely for information without any liability on part of Clyde Bergemann neither is it the basis to any claim or third
parties.
3. Lubricants of different consistencies should not be mixed.

Shanghai Clyde Bergemann Commission SC10116


Project: TALWANDI 4X660MW Page: - 43 -
Non-Cooling Thermoprobe
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2. Track beam
2.1 Track beam rails
In case of high accumulation of dust in the boiler house the slide rails of the probe
carriage are to be blown with compressed air, particularly after boiler repairs or the like.
2.2 Toothed rack
Depending on the degree of contamination the toothed rack is to be cleaned and
relubricated (refer to list of lubricants) at regular intervals, approx. every year, thereby
the wear and tear of pinion and toothed rack should be checked, as well.
2.3 Probe tube guide
The probe tube guide is equipped with double-sided sealed ball bearings which are
provided with long-term grease filling for higher temperature. Therefore these ball
bearings need no service.

3. Probe carriage
3.1 Gear and motor
1. The spur worm gear will be delivered with a long-term lubrication of synthetic oil.
2.Only after about 10000 operating hours of the motor, at least however after 5 years, a
thorough cleaning of the gear and new filling with lubricant indicated in the list of
lubricants is recommended.
3.The required quantity of lubricant for the new filling is indicated on the rating plate as
regenerate value.
4.Take care that motor and gear form one unit. Depending on the mounting position of the
probe the gear oil is to be drained off before the motor is dismounted. The sealing surface
between motor and gear is to be thoroughly cleaned and provided with sealing compound.
3.2 Bearings and support rollers
The bearings and supporting rollers of the probe carriage needs no service.

4. Probe tube and Probe Head


The probe tube is to be checked at regular intervals for deformation and possible
damage caused by corrosion.

Shanghai Clyde Bergemann Commission SC10116


Project: TALWANDI 4X660MW Page: - 44 -
Non-Cooling Thermoprobe
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5. Power Supply System
The movement sequence of cable and power supply system must be checked
regularly.

Shanghai Clyde Bergemann Commission SC10116


Project: TALWANDI 4X660MW Page: - 45 -
Non-Cooling Thermoprobe
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Section D 2 Maintenance of the Thermo probe

1. Replacement of the thermo element


2. Dismounting and mounting of the probe tube
3. Dismounting and mounting of the probe carriage

________________________________________________________________
Attention!
These works must be carried out only by qualified personnel.

Any deviation from the instructions contained in


this manual will render any guarantees null and void!

Shanghai Clyde Bergemann Commission SC10116


Project: TALWANDI 4X660MW Page: - 46 -
Non-Cooling Thermoprobe
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1. Replacement of the thermo element


Make sure that the motor of the probe cannot be switched on.
Detach the thermo-couple lead wire form the thermo element.
Unscrew the thermo-element.
Mounting follows in reverse order.
Now the probe can be put into operation again.

2. Dismounting and mounting of probe tube


Make sure that the motor of the probe cannot be switched on.
Detach the thermo-couple lead wire form the thermo element.
Loosen the screws from the probe flange.
At pulling out the probe tube attention must be paid that the thermo-element will
not be damaged.
Now, the thermo-element can be removed.
Mounting of the probe tube and thermo element is carried out in reverse
sequence. After operation of the probe all screwed connections are to be
checked.

3. Dismounting and mounting of probe carriage


Make sure that the motor of the probe cannot be switched on.
Detach the thermo-couple lead wire form the thermo-element.
Following remove the position sensor and fixation bracket. At removing the
position sensor attention must be paid that the measuring rope will not resile.
(Damage of the sensor!)
Loosen the motor cable.
Unscrew the holding device of the energy chain.
The probe carriage can be moved backwards by means of the hand crank. As
soon as the drive pinion is run off the toothed rack, the carriage is removed from
the rail.
Mounting of the probe carriage is carried out in reverse sequence. After operation of the
probe all screwed connections are to be checked.

Shanghai Clyde Bergemann Commission SC10116


Project: TALWANDI 4X660MW Page: - 47 -

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