Pp10 CCGT Power Station: Sootblower Operation and Maintenance Manual

3 Update PS GS 18/Apr/2013
2 Update PS GS 19/Jul/2012
1 Update PS GS 16/Jun/2012
0 FIRST ISSUE PS GS 11/May/2012
REV DESCRIPTION PREP CHKD CHKD APPD DATE
PROJECT
PP10 CCGT POWER STATION

CONTRACT NO: 31121111 / 00
CLIENT
CONSULTANT
CONTRACTOR:
DRAWING TITLE:
Sootblower Operation and Maintenance Manual
COMPANY/ORIGINATOR: PROJECT DOCUMENT NUMBER: REV.
PP10CC-00-HCB-NEM-001 A
VENDOR DOCUMENT NUMBER: REV.
21036-553-04-008-001 3
DISTRIBUTION CODE: SHEET No. SIZE SCALE:
MECHANICAL 1 OF 78 A4 -
FILE NAME
PP10CC-00-HCB-NEM-001-REV A
Rev 1.0 Page 1 of 78

INSTRUCTION MANUAL
DIAMOND IK1M-TE
Electric Motor Driven Sootblower
Contract N11485
Diamond Power Specialty Limited

Block 10, Vale of Leven Indy. Est.,
Dumbarton.
Scotland G82 3AD
Tel: Dumbarton +44 (0)1389 727900

Fax: Dumbarton +44 (0)1389 757405

THIS INSTRUCTION MANUAL AND THE INFORMATION CONTAINED WITHIN IT HAVE
BEEN FURNISHED FOR USE BY YOUR ORGANISATION ONLY AND FOR THE
PURPOSES CONSISTENT WITH THE TRANSACTION BETWEEN YOUR ORGANISATION
AND DIAMOND POWER. NO COPIES OF OR ANY DATA FROM THIS MANUAL SHALL BE
FURNISHED TO ANY THIRD PARTY WITHOUT THE WRITTEN AGREEMENT OF:
 +44 1389 727 900

 +44 1389 757 405 (fax)
 www.diamondpower.co.uk
 Diamond Power Speciality Ltd

Block 10
Vale of Leven Industrial Estate
Dumbarton,
Scotland. G82 3AD
ELECTRICAL SAFETY WARNING

Electrical Motors and Components are designed for operation in Industrial
Applications and in normal service there is a possible danger from rotating parts
and/or live terminals.
It is essential that motors and other electrical components are installed or serviced
by qualified personnel in order to avoid injury or death and/or damage to euipment
or installations.
If there are any safety concerns regarding any piece of electrical equipment,
please contact your nearest sales or service office for advice or assistance.
If there are any doubts about safety, do NOT install the unit or attempt to operate it.
We cannot be held responsible for damage as a result of installation or service by
unqualified personnel.

TABLE OF CONTENTS
1. CONTRACT IDENTIFICATION ................................................................................................................. 7
1.1 CONTRACT IDENTIFICATION ................................................................................................. 7
2. GENERAL DESCRIPTION .......................................................................................................................... 8
2.1 Introduction ................................................................................................................................ 8
2.2 Sootblower Identification ............................................................................................................ 8
2.3 Operating Cycle ......................................................................................................................... 8
2.4 Manual Operation....................................................................................................................... 9
2.5 Safety Information .................................................................................................................... 11
2.6 Cleaning Principle .................................................................................................................... 11
3. COMPONENT DESCRIPTION.................................................................................................................. 12
3.1 Mechanical Layout ................................................................................................................... 12
3.2 Beam Assembly ....................................................................................................................... 13
3.3 Front Roller Support Assembly ................................................................................................ 13
3.4 Wallbox .................................................................................................................................... 14
3.5 Pressure Regulating Valve....................................................................................................... 14
3.6 Rear Support ............................................................................................................................ 15
3.7 Carriage & Drive Mechanism ................................................................................................... 15
3.8 Guide Assembly ....................................................................................................................... 16
3.9 Leadscrew Assembly ............................................................................................................... 16
3.10 Poppet Valve Operation ........................................................................................................... 17
3.11 Air Relief Valve......................................................................................................................... 18
3.12 Feed Tube ................................................................................................................................ 19
3.13 Lance Tube .............................................................................................................................. 19
3.14 Lance Tube Support ................................................................................................................ 20
3.15 Element .................................................................................................................................... 20
3.16 Blowing Medium Operation & Flow Path – Positive Pressure.................................................. 21
3.17 Electrical................................................................................................................................... 22
4. INSTALLATION INSTRUCTIONS ........................................................................................................... 24
4.1 Lifting the Sootblower............................................................................................................... 24
4.2 Sootblower Mounting / Installation ........................................................................................... 25
5. MAINTENANCE INSTRUCTIONS ........................................................................................................... 27
5.1 General .................................................................................................................................... 27
5.2 Manual Operation for Setup or System Check ........................................................................ 27
5.3 Lubrication................................................................................................................................ 29
5.4 Carriage Lubrication ................................................................................................................. 29
5.5 IK1M Lubrication Chart ............................................................................................................ 29
5.6 Maintenance Schedule............................................................................................................. 30
5.7 Special Tools............................................................................................................................ 30
5.8 Fault Finding ............................................................................................................................ 33
6. MAINTENANCE WORKSHEETS............................................................................................................. 34
6.1 Pressure Sealing Points – Checking Procedure ...................................................................... 34
6.2 Feed Tube Packing .................................................................................................................. 36
6.3 Poppet Valve Maintenance ...................................................................................................... 37
6.4 Adjusting Blowing Medium Turn-on Linkage............................................................................ 38
6.5 Poppet Valve: Removal from Sootblower ................................................................................ 39
6.6 Poppet Valve Dismantling for Valve Seat Lapping................................................................... 40
6.7 Poppet Valve Stem Packing Adjustment & Renewal ............................................................... 41
6.8 Poppet Valve Tools & Equipment /Lapping the Valve Seat ..................................................... 42
6.9 Poppet Valve – Re-assembly ................................................................................................... 43
6.10 Poppet Valve – Replacing on the Sootblower .......................................................................... 44
6.11 Lance Tube / Gasket – Adjusting & Removal Procedure ........................................................ 46
6.12 Removal of Carriage from Sootblower ..................................................................................... 48
6.13 Carriage Dismantling: Drive Pinion & Worm Gear ................................................................... 49
6.14 Wallbox Dismantling / Replacement ........................................................................................ 51

6.15 Limit Switches – Renewal & Adjustment .................................................................................. 52
7. PARTS IDENTIFICATION......................................................................................................................... 53
7.1 IK1M Sootblower Main Assembly ............................................................................................ 54
7.2 Carriage Assembly - Standard ................................................................................................. 56
7.3 Electrical Control Assembly- Limit Switch Arrg’t ...................................................................... 58
7.4 Lance Joint & Packing Assembly ............................................................................................. 60
7.5 Steam Turn-On Assembly........................................................................................................ 62
7.6 Blowing Medium – (Steam Turn-On Assembly) ....................................................................... 64
7.7 Poppet Valve Assembly ........................................................................................................... 65
7.8 Wallbox Assembly – Scavenge Line Assembly – Positive Press. ........................................... 67
7.9 Air Relief Valve – Positive Pressure......................................................................................... 69
7.10 Fold Flat Guard Assembly........................................................................................................ 70
7.11 Rear Cover Assembly – Acoustic Cover .................................................................................. 72
7.12 Front Roller Assembly .............................................................................................................. 74
7.13 Front Roller Wheel Assembly .................................................................................................. 75
7.14 Limit Switch Trip Assembly ...................................................................................................... 76
7.15 Rear Support Assembly ........................................................................................................... 77
7.16 Carriage – Motor & Guide Block Sub Assembly ...................................................................... 78

1. CONTRACT IDENTIFICATION
1.1 CONTRACT IDENTIFICATION
Diamond Contract No. N11485

Customer NEM Energy bv
End User Site Saudi Electric Company, Riyadh PP10
Position No. Serial No. Unit No. Tag No.
For Information Refer to

Equipment Supplied General Arrangement Drawing
640 Off IK1M-TE 21036-553-04-126-001
Customer Order No.
HEAD PRESSURE SETTINGS AND CORRESPONDING FLOWS ARE

RECOMMENDED INITIAL VALUES AND SHOULD BE ADJUSTED AS
OPERATING EXPERIENCE DICTATES, EXCEPT THAT FLOWS SHOULD NOT
BE REDUCED BELOW MINIMUM COOLING FLOW.
HEAD PRESSURE SETTINGS ARE LISTED AS A CONVENIENT METHOD OF
Blowing Pressure SETTING FLOW RATES.
IF MORE ACCURATE FLOWMEASURING DEVICES ARE USED, THE
PRESSURES SHOULD BE SET TO GIVE THE FLOW RATES INDICATED.
INLET PRESSURE IS SOURCE PRESSURE LESS PIPE LINE LOSSES. IT
MUST BE SUFFICIENT FOR HEAD PRESSURE AFTER VALVE INLET
PRESSURE LOSSES.
Revisions
Rev Description Date By

1.0 First Issue – IK1M-TE Jun. 2012 P. Stewart

2. GENERAL DESCRIPTION
2.1 Introduction
This Instruction manual covers the IK1M-TE Sootblower and should be used in conjunction with the
relevant layout sheets.
This Operating & Maintenance Manual (008) includes:-
013 Training Instructions
The IK1M is a 1.3 metre travel sootblower powered by a travelling motor drive which, through reduction
gearing and leadscrew, drives a carriage along a supporting guide tube. A lance tube, attached to the
carriage, propels an element across the boiler. Blowing medium, controlled by an integral poppet valve,
is fed to the element via a feed tube.
The IK1M sootblower can be operated from a remote control panel. – Refer to Control systems
Instruction Manual for operation details Ref. 21036-553-04-008-002.
2.2 Sootblower Identification

Each sootblower in an installation is identified by a serial number and a position number, both of which
are marked on the sootblower nameplate.
2.3 Operating Cycle

The operating cycle begins with the IK-1M in the fully-retracted (reset) position. When power is applied to
the drive motor, the carriage moves forward tripping the intermediate limit switch to alert the system that
a cleaning operation is in progress. A trip pin on the carriage operates the poppet valve linkage to open
the poppet valve, admitting blowing medium to the cleaning element. The carriage continues its forward
movement until it operates the front limit switch via a trip bracket on a guide assembly fitted to the
carriage. This action reverses the drive motor direction, reversing the carriage movement. Before
reaching the return position the bracket will activate the intermediate limit switch and send a signal to
the control panel to show completion of one blowing cycle and start the next sootblower in the sequence.
As the carriage reaches its retracted position, the trip pin again operates the valve linkage this time to
close the valve. The trip bracket operates the rear limit switch to stop the sootblower at the reset
position.

2.4 Manual Operation
IMPORTANT SAFETY NOTICE:

Before attempting to operate the unit in Manual Mode,
It is essential that the Electrical Mains Supply has been disconnected
During maintenance, or in an emergency, the sootblower carriage can be operated manually by using
the square drive ratchet tool. Rotate the locking pin through 90 degrees and pull horizontally to unlock
the leadscrew. The square tang can now be rotated anti-clockwise which results in the carriage travelling
forward and the lance tube going into the boiler. Conversely, turning the square tang clockwise results in
the carriage returning towards the fully-retracted position. Additionally the 18 tooth sprocket on the
carriage assembly can be locked by moving the locking plate arrangement vertically by 10mm to engage
the sprocket teeth.
View on Rear Bulkhead Assembly
Anti-Clockwise Rotation Of
Square Tang
Manual Operation
Square Tang Locking Pin
Wrench
Rear
Bulkhead
Stop Pin

Manual Operation – Locking Plate
Locking Plate
Locking
Screw
Plate Plate
Locked Position Un-locked Position
Occasionally, during manual operation, the drive nut rotates in unison with the leadscrew. This action
prevents the carriage from moving.
This situation can be prevented by raising the locking assembly so that it engages with the 18T sprocket
as shown above.
The locking assembly should be set in the UNLOCKED position for normal duty. For hand operation,
loosen the M6 screws; raise the locking assembly 10mm to the LOCKED position, so that the Lock is
engaged with the 18T sprocket.

2.5 Safety Information
Please ensure that all relevant personnel are made aware of the following safety information.
WARNING
SOOTBLOWER
Keep clear and be aware of the following:-

• The sootblower may be remotely operated and may start without warning.
• Various mechanical components of the sootblower will move.
• The sootblower is supplied with blowing medium - TURN SUPPLY OFF ELSEWHERE.
• The supply valve may open to admit high pressure/temperature blowing medium.
• Various surfaces of the sootblower may become very hot.
• The sootblower is supplied with live electrical supplies - ISOLATE ELSEWHERE.
• To STOP the sootblower switch the main electrical supply OFF, the sootblower may re-
start when supply is switched ON, blowing supply may remain ON until SB is at rest.
Do not operate the sootblower locally unless permitted to do so.

Do not carry out maintenance until blowing medium supply valves are
locked closed and all voltage supplies are locked OFF.
2.6 Cleaning Principle

The basic function of the sootblower is to clean the heating surfaces of the boiler by the impact energy of
high-pressure air, or steam, which is delivered by a multi-nozzle openings positioned in a travelling
element which traverses the area to be cleaned and then returns to the reset position ready for the next
cleaning cycle. The element is permanently situated inside the boiler and is designed on a contract
basis, to give maximum cleaning effect.
Typical Nozzle Cleaning Pattern
Travelling Element – Rotating

Maximum 1.3m Travel

3. COMPONENT DESCRIPTION
3.1 Mechanical Layout
The IK1M sootblower comprises a number of sub-assemblies as described in this section.
A comprehensive breakdown of the components is given in Parts Identification section 7.
Main Assembly Components
Rear Support Assembly
Cam Assembly
Support
Rollers
Terminal Box
Drive Motor
Air Relief Valve
Square Tang
Poppet Valve (Manual Operation)
Companion Flange
Guide Tube
Assembly
Rear Limit
Switch
Intermediate Limit Switch
Leadscrew
Front Limit
Switch
Carriage
Assembly
Lance
Front Bulkhead Positive Wallbox

3.2 Beam Assembly
The beam is a fabricated steel assembly comprising a pressed-steel canopy with front and rear
bulkhead plates. It provides support and protection for the sootblower mechanisms. Lugs, integral to the
beam assembly, provide lifting points and a mount for the support bracket assembly used in service.
A second lifting point is provided within the front bulkhead. Guarding to the underside of the unit is
shown.
Beam Assembly
Front Lifting Point
Support Bracket
Assembly
Seal Panel
Front
Bulkhead
Beam
Guards
Rear Bulkhead
3.3 Front Roller Support Assembly

Roller assemblies support and guide the rotating lance tube as it travels. The support rollers are
positioned such that the axis of rotation of each roller is at right angles to the helical contact path of the
lance tube.
Front Roller Support Assembly
Positive Wallbox
Lance Tube Bulkhead Assembly
Support Rollers

3.4 Wallbox
Positive Pressure
The wallbox assembly consists of fabricated steel housing which incorporates a twin seal plate and air
seal arrangement. The function of a wallbox is to provide a mounting point for the front of the blower,
and to provide an air seal where the lance enters the boiler through the wallsleeve. The wallbox is
pressurised so that if the gas pressure inside the boiler is above atmospheric pressure, the flue gases
are prevented from escaping through the wallbox. The scavenge air prevents gas from travelling through
the lance and into the feed tube. Seal air is introduced into the wallbox via a connection located on the
topside of the wallbox. Air must be available at all times during operation, whether or not the
sootblowers are in use. Air must also be available during the water washing to prevent water entering
the nozzles.
A connection from the sealing air line also runs to the air relief valve to scavenge the poppet valve, feed
tube and lance tube.
WARNING: In a positive pressure boiler installation, failure to connect a positive wallbox
to an air supply may result in flue gases being drawn into the lance and through the poppet
valve. This may cause corrosion damage, which may be significant.
Positive Pressure Wallbox
Scavenge Air Pipe &

Components Seal Plate Mounting Flange
Hex Seal Plate

Adjusting Screws
Seal Plate
Bulkhead Assembly
For an itemised parts list of the wallbox assembly, refer to section 7.9
3.5 Pressure Regulating Valve

A pressure regulating valve is provided at the sealing air entry to the wallbox. The valve must be
connected to the sealing air line and adjusted to maintain adequate sealing air within the wallbox.
A connection from the sealing air line also runs to the air relief valve to provide a scavenging function.

3.6 Rear Support
The sootblower is supported at the rear by a support bar, screwed rod and integral support lug
arrangement. The rear support bar assembly is assembled on site to the structural steelwork.
Rear Support
Cam Mounting Plate

Locknuts
Top Cover Plate
Rear Support Bar Integral Support Lugs
Split Pin
3.7 Carriage & Drive Mechanism

The IK-1M is driven by a motor which is flange-mounted to the carriage housing and drives the carriage
via a worm reduction gear and drive nut arrangement housed within the carriage.
The drive nut, keyed to the worm gear, traverses a stationary leadscrew as it rotates. Direction and
extent of travel are controlled by limit switches.
The lance tube, flange-mounted to the lance hub, is rotated by a chain and drive sprocket arrangement.
Where the element is fixed in position, the lance hub drive arrangement is omitted.
Carriage & Square Shaft Drive Assembly
Worm Gear
Drive Nut
Carriage
Drive Sprocket Stationary

Leadscrew
Lance
Lance Hub Worm Shaft Drive Motor

3.8 Guide Assembly
A guide assembly, comprising a mounting plate and two guide blocks, is bolted to the carriage housing.
A guide tube which runs the length of the beam is located at one end in the front bulkhead. The rear end
of the guide tube is retained by two circlips pins on either side of the rear bulkhead.
Guide Assembly
Leadscrew
Mounting Plate
Guide Block
Guide Tube
Trip Bracket
Motor/Carriage Housing
Retaining Ring
As the carriage travels forward, the guide assembly slides along the supporting guide tube. A trip
bracket, bolted to the forward guide block, actuates the limit switches which control the travel of the
sootblower.
3.9 Leadscrew Assembly

When the locking pin is removed, the leadscrew can be rotated to drive the carriage manually. A square
tang is provided on the end of the leadscrew for attaching a ratchet wrench. Collars, pinned to the
leadscrew prevent axial movement of the leadscrew during forward and reverse travel.
Leadscrew Assembly
Adjustable Stop Retaining Ring Square

Drive Nut Tang
Leadscrew
Locking Pin
Keep Roll Pin
Front Bulkhead
Locating Collar

3.10 Poppet Valve Operation
The poppet valve controls the flow of blowing medium to the lance and is operated mechanically by a
cam and trigger arrangement. The valve seat is welded into the valve body and is of a flexible
construction to allow for thermal expansion. The sealing face of the valve has a hard deposited surface.
The valve stem is positioned by the valve stem guide that is screwed into the valve body. A pressure
control disc is screwed onto the lower part of the guide and is locked in position by a lock pin.
The upper part of the stem guide contains the valve stem packing which seals around the stem to
prevent leakage of the blowing medium. A packing nut, screwed onto the stem guide, compresses the
packing through a packing washer. The packing nut also supports the valve spring which acts on the
stem through the valve yoke. The valve yoke secures the spring retainer and is located in a recess on
the upper part of the stem. An integral inlet flange mates with the associated companion flange and
gasket. The valve outlet has a flange which is bolted to a mounting on the sootblower.
Poppet Valve – Section View
Valve Trigger
Spring
Stem & Disc Assembly
Valve Stem Packing
Lock Pin
Pressure Control
Disc
Valve Seat
Valve Body
Companion Flange
Gasket
Companion Flange
The poppet valve is operated mechanically via a cam and trigger arrangement. A trip stud mounted on
the carriage actuates the cam. As the carriage moves forward, the stud pivots the cam, thus pulling the
valve trigger forward. The valve trigger pivots and depresses the valve stem, thus opening the valve and
admitting blowing medium to the feed tube. Each poppet valve is fitted with an air relief valve.

Poppet Valve - Operation
Cam
Adjusting Rod Mounting Plate
Trigger
Arrangement
Cam Assembly
Carriage Trip Pin

Poppet Valve
Assembly
Feed Tube
3.11 Air Relief Valve

On positive pressure installations, a connection from the sealing air line to the wallbox is piped to the air
relief valve, to provide the scavenge function.
In either case, the action of the air relief valve prevents the blowing medium from escaping from the
sootblower into the sealing air line when the sootblower is operating
Air Relief Valve
To Scavenge Air Inlet/

Atmospheric
Connection
To Poppet Valve

3.12 Feed Tube
Blowing medium is admitted to the feed tube when the poppet valve opens at the start of the cleaning
cycle and passes through it into the lance tube. The feed tube is seated within the lance tube in the fully-
retracted position; the blowing medium is sealed by packing in a gland in the carriage hub. The outside
diameter of the feed tube is highly-polished to minimise packing wear as the lance hub slides over it
during the cleaning cycle.
The end of the feed tube is sealed against the gasket in the poppet valve outlet by a clamping plate
which also secures the valve to the poppet valve mounting. The feed tube is keyed to prevent rotation.
Feed Tube Packing Arrangement
Carriage
Carriage Hub
Flange Gland
Lance Tube
Feed Tube
Gland Gasket
Packing Bushing
3.13 Lance Tube

The lance tube directs the flow of blowing medium to the element. The flanged end of the lance tube is
bolted to the hub on the carriage, as shown in Fig above, and moves with it. The other end of the lance
tube is generally supplied prepared for welding to the element on-site.

3.14 Lance Tube Support
The lance tube normally rotates as it travels and is supported by rollers mounted on shafts welded to the
adaptor plate. The roller shafts are angled to ensure that full rolling contact is made between the rollers
and the lance tube as it travels.
Lance Tube Support
Wallbox
Element
Lance Tube
Boiler Wall
Rollers
Wallsleeve
3.15 Element
The element is designed to clean the heating surface using a series of nozzles arranged to suit the
particular operation. The size and number of nozzles are determined by the cleaning requirement.
Normally, the element is welded to the end of the lance tube on site.
Blowing medium is directed at the area to be cleaned by the nozzles as the element traverses the boiler
tubes. This action removes slag, ash, or any other deposits from the area to be cleaned.
Suitable supports should be provided for the cleaning element, as illustrated on the General
Arrangement Drawing 21036-553-04-126-001

3.16 Blowing Medium Operation & Flow Path – Positive Pressure
Air Seal Inlet
Blowing Medium
Turn-On Linkage
Lance
Wallbox
Feed Tube
Feed Tube Packing
Packing Gland Assembly

Air Releif Valve
Poppet Valve Assembly

Valve Stem & Disc Assembly
Companion Flange
Blowing Medium
When a positive pressure wallbox is attached to a boiler that is on-load, sealing air must always be
available to prevent corrosive or dangerous gases from escaping into the air relief valve, poppet valve,
feed tube and lance. Sealing air is introduced through the air seal inlet to the wallbox of the sootblower.
The pressure applied is greater than the boiler pressure by approximately 150mm WG and forms an air
seal between the lance and wallbox.
A scavenging tapping is taken from the air inlet and is fed to the poppet valve through an air relief valve.
This action provides an air supply that will prevent any boiler gases from damaging the internal
components of the poppet valve and will help to prevent corrosion in the feed tube and lance.
During a cleaning cycle, the carriage movement towards the boiler, causes the trip pin mounted to the
carriage, to engage with a beam mounted cam assembly. This action causes the blowing medium turn-
on linkage to turn the blowing medium on by depressing the valve stem and disc assembly.
The blowing medium enters the poppet valve through the pipework welded to the companion flange.
Blowing medium pressure will cause the air relief valve to close and this will stop the blowing medium
from entering the air scavenging piping. The cleaning operation will continue until the lance has returned
to its rest position and the valve stem disc assembly has closed, allowing sealing air once more to enter
the poppet valve and feed tube.
Leakage from the feed tube is prevented by adjustable feed tube packing which is held in position by a
packing gland assembly.

3.17 Electrical
Electrical components on the sootblower comprise a drive motor, forward, intermediate and rear limit
switches and terminal box. The wiring between the drive motor, limit switches and terminal box is part of
Diamond Power supply. The interconnecting wiring from the sootblower to the electric control panel is
not part of Diamond Power supply. To complete the electrical link between the sootblower and the
control panel a wiring diagram will be supplied by Diamond Power. (Refer to Technical Data, Section 7.)
When the motor is energised from the control panel it drives the carriage forward and the bracket,
mounted to the guide block assembly, will trip the intermediate limit switch to alert the system that a
cleaning operation is in progress. The carriage will continue forward until the bracket activates the
forward limit switch, confirming the end of the forward cleaning cycle. This action reverses the drive
motor and starts the reverse cleaning action.
The carriage will continue to the fully retracted position. Before reaching the return position the bracket
will activate the intermediate limit switch and send a signal to the control panel to show completion of
one blowing cycle and start the next sootblower in the sequence. The carriage will continue until it trips
the rear limit switch, causing the motor and the travel to stop. The motor rotation will be reversed to
await the next forward operation.
Limit Switches
Limit switches, are mounted directly onto a mounting rail. They control forward and reverse travel. The
front switch (LSF) reverses the sootblower at full extension, while the rear switch (LSR) stops the
sootblower in the reset position. The Intermediate limit switch is used as a sequencing alert to provide
feedback that will allow the next sootblower in the cleaning process to begin operation.
Limit Switch Layout
Rear Limit Switch

Sequence Limit Switch (Intermediate)
Front Limit Switch
Terminal Box
Mounting Rail
Motor
Carriage
A sequence switch, when fitted, operates the next sootblower in turn. Travel limits can be altered by
adjusting the position of the switches on the mounting rail. The switches are actuated by a trip bracket
on the guide assembly fitted onto the carriage
Full information on the control and electrical operation of the sootblowers will be found in the Controls
Instruction Manual, Ref: 21036-553-04-008-002

Limit Switches
The typical limit switch and mounting rail assembly is shown below.
The limits switches are mounted on perforated rail and adjustment is made by repositioning along the
rail.
Rear Limit Switch Assembly
Mounting Rail
Rear Limit
Switch
Assembly
Front Limit
Switch
Assembly
Terminal Box
Sequence Limit Switch /

Intermediate

4. INSTALLATION INSTRUCTIONS
General
General arrangement drawings are supplied with each set of sootblowers. These drawings show the
location of the sootblowers in the installation, the blowing medium pressure, overall dimensions, method
of mounting, extent of Diamond Power equipment supplied, and connections to be made.
Handling Packed Equipment
Sootblowers which are packed in boxes or crates must be handled by slinging the boxes, using two
slings. Boxes and crates supplied are specially reinforced for the purpose.
Receipt at Site
On receipt at site, it is recommended that IK1M sootblowers should be removed from their crates or
boxes, all polythene wrappings removed, and the equipment stored in a dry building where temperature
and humidity are controlled to prevent condensation. Sootblowers should be stored the correct way up
and not on their sides. Inspect for damage from shipment or storage. Ref Storage & Handling Doc Ref:
21036-553-04-011-001
4.1 Lifting the Sootblower

When lifting the sootblower into position, the lifting lugs provided on top of the beam should be used.
Caution: Do not use a sling around the beam or the protruding lance tube, as this may cause
damage and subsequent malfunctioning.
Sootblowers should only be moved by slinging from the lifting lugs provided on the top of the beam. Use
of a two-point sling or fork lift truck is likely to cause damage and prevent proper operation when
installed.
Typical Slinging Arrangement.
During storage, sootblowers should be inspected at monthly intervals. Particular care should be given to
ensuring that the closures (tape, caps. etc.) on all openings remain intact.
Note
Do NOT lift the sootblower with slings in any unsupported area as this can cause side wall distortion.
Lifting in unsupported area danger.
Do Not Sling Around Beam

4.2 Sootblower Mounting / Installation
Location
Each sootblower is identified on the appropriate installation drawing by a serial number; this number is
marked on the sootblower nameplate. Care must be taken to ensure that each sootblower is installed in
its correct location.
Remove the wallbox flange from the blower and weld it to the wallsleeve, ensuring that the holes are
positioned as shown on the layout sheet in the technical data section of this manual.
When fitting the blower to the boiler, provide temporary support and observe the following:
a. Position the wallbox seal plates with the machined face of the front seal plate towards the
wallbox flange.
b. Apply Dow Corning 744 silicone sealant to the faces of the wallbox housing.
c. Position the wallbox housing with the seal air inlet as shown on layout sheet.
d. When the M12 mounting bolts are tightened, the wallbox seal plates must be adjusted to give
the correct clearance by turning the four M10 seal plate adjusting screws clockwise until there is
th
no seal plate movement. Turn each screw counter-clockwise by 1 flat (1/16 . Turn)
Check that the seal plates are free to move.
e. Connect the flexible pipe between the seal air inlet tee and the scavenge air connection as
shown on the layout sheets in technical data section.
The adjustable rear support should be attached to the steelwork designed and supplied by the
customer. Provided relative expansion at the boiler is small, the rear end may be tied to the boiler wall. It
is not recommended that the rear of the boiler should be supported from cold steelwork, gallery
structures etc. as the relative expansions between this and the boiler could affect the blower alignment.
The adjustable rear support can be used to provide proper alignment with the boiler on load.
Downward boiler expansion on heating is taken as positive (+)

Upward boiler expansion on heating is taken as negative (-)
Both horizontal and lateral alignments should be checked when the boiler is hot and on load.
Steam supply branch line piping should be designed to take care of the boiler expansion in all directions.
It must also take care of steam supply piping expansions and have a minimum drainage slope, towards
the main, of not less than 40mm per metre when the boiler is hot. Steam mains should have the same
minimum drainage slope toward the drain point.
For reliable operation of the sootblower, it is absolutely essential that the sootblower, the element and
the element bearings are correctly aligned when the boiler is hot. I.e. when the blower is in its normal
running condition. Failure to ensure this may result in very high friction, reducing the life of the
sootblower, or the sootblower stalling during operation. It is essential that the lance to element joint and
any element joints are completely straight as any misalignments will give rise to similar problems.
The air pressure in the wallbox should be 150mm (W.G.) above the furnace pressure, use the pressure
tapping in the wallbox to check this.
The blowing pressure should be set to the value quoted on the steam data chart.
After the blower has been operated a few times with live steam, the feed tube packing should be
checked and adjusted to compensate for bedding in.
Fit the companion flange to the sootblower inlet flange and. tighten the studs as per the sequence in the
detail below.

Stud Tightening Sequence
1 5
8 3
4 7
6 2
Connect the sealing air pipework to the wallbox. (Positive pressure applications only)
Observe the alignment of the beam arrangement: check for any bends, twists or other distortions.
Make the power and control connections to the sootblower terminal box; ensure that there are no loose
terminals or wiring. Leave the sootblower ready for commissioning with the local isolation switches off
and the blowing medium supply isolated. Fit guards (When Applicable) after commissioning. (Refer to
installation drawing - Technical Data Section)
Customer Supply: Steam Pipework, Supporting Steelwork, Wallsleeves, Tube Plates.

Diamond Supply: Sootblower, Guards, Jet Element, Jet Element Support Bearings, Seal
Air Regulating Valve with Connection Flange, Companion Flange studs, nuts and
gasket, Dow Corning 744 silicone sealant.

5. MAINTENANCE INSTRUCTIONS
5.1 General
Maintenance instructions in this Section are grouped under the following headings:
Manual Operation for Setup or System Check
Lubrication
Carriage Lubrication
IK1M Lubrication Chart
Maintenance Schedule
Optional Tools
Fault Finding
5.2 Manual Operation for Setup or System Check

For maintenance, or in an emergency, the sootblower can be operated manually by using the emergency
winder adaptor. Refer to Manual operation section 2.4, for detailed information.
Note
The sootblower must always be returned to the fully retracted position after manual operation to reset
the limit switches.
If a fault develops with a set of sootblowers during automatic sequential operation, the sootblowers
should retract automatically. If they fail to do so for any reason, such as power failure, motor stalled, etc.,
immediate action must be taken to withdraw the sootblowers involved.

General Maintenance Tasks
Maintenance Operation Sectio

Job to be Performed Lubrication Interval
n Ref.
Poppet Valve to Companion Flange Pressure Sealing Point 6.1 Monthly
Feed Tube to Poppet Valve Pressure Sealing Point 6.1 Monthly
Lance Tube Pressure Sealing Point 6.1 Monthly
Feed Tube Packing Check for Leak 6.2 Monthly
Poppet Valve Maintenance Check Blowing Pressure 6.3 Monthly
Blowing Medium Turn-On Linkage Check Correct Setting 6.4 Monthly
Poppet Valve Removal from Blower Major Overhaul 6.5 AsRequired
Poppet Valve Dismantling Valve Seat Lapping 6.6 AsRequired
Poppet Valve Stem Packing Check for Leakage 6.7 Monthly
Lance Tube Gasket Check for Leakage / 6.11 Monthly
Renewal
Carriage Removal Major Overhaul 6.12 AsRequired
Carriage Dismantling - Drive Pinion & 6.13 AsRequired
Major Overhaul
Worm Gear
Wallbox Dismantling Major Overhaul 6.14 AsRequired
Limit Switches - Renewal & 6.15 AsRequired
Travel Reset or Adjustment
Adjustment
Poppet Valve including Air Relief 3.10 Weekly
Check for deterioration
Valve 3.11
Feed Tube Check for deterioration 3.12 Weekly
Lance Tube Check for deterioration 3.13 Weekly
Support Rollers Check for deterioration 3.3 Weekly
Limit Switches Check for deterioration 3.12 Weekly
Manual Operation Check Blower Operation 2.4 Weekly
Carriage 5.3 Mobilith Monthly

Lubrication
SHC007
Drive Chain 5.3 Light Monthly
Lubrication
Machine Oil
Leadscrew (Through Bulkhead) 5.3 Light Monthly
Lubrication
Machine Oil

5.3 Lubrication
General Lubrication – Gear Reducer & Carriage
To maintain the efficiency of the IK-1M Sootblower, it is essential that periodic checks are carried out at
the lubrication points listed in this Section.
Should the carriage require dismantling, the lubricant should be replaced as follows: - worm and spur
gear cavities: - 385 - 400g Mobilith SHC007 or Rocol “Sapphire Extreme” into each cavity.
If any bolts are temporarily removed from the sootblower, the heads and threads should be coated with
an anti-seize compound, such as Molykote G-n or Thread-Guard, before replacement.
5.4 Carriage Lubrication

The worm set cavity of the carriage, is factory-lubricated and sealed for life. When the carriage requires
dismantling, the lubricant should be renewed after reference to lubrication chart.
5.5 IK1M Lubrication Chart
LUBRICATION PART TO BE MEANS OF

COMPONENT LOCATION LUBRICANT / PERIOD
POINT LUBRICATED LUBRICATION
Rocol Sapphire Extreme

Fill each cavity
(High Temp ≥350°C
Under Worm and with
Carriage* Sootblower Shaft Gearing 385 - 400g
Beam Cavity (13.6 – 14.0
Mobilith SHC007
fl.Oz)
(Universal)
At Rear of
Drive Chain Chain Links Chain Spray or Brush Light Machine Oil
Carriage
Leadscrew Rotates
Through through Ends only of
Bulkhead Brush with Light Machine Oil
sootblower Leadscrew
* “Sealed for Life” but may be re-lubricated

if stripped down at Major Overhaul.

5.6 Maintenance Schedule
General
Sootblower controls should be arranged to protect the plant and the sootblower from damage in the
event of a fault developing.
The Maintenance Schedule is designed to maximise sootblower availability.
Periodic Inspection
Frequency of this inspection will depend on operating conditions, but should not be less than once per
month. Points to be checked are;
All mechanisms are functioning properly.
Blowing medium is not leaking.
All moving parts are adequately lubricated. Do not lubricate excessively
Routine Maintenance
Routine maintenance should be carried out annually, with the sootblower in situ and with all services
connected, but isolated as appropriate. Gaskets and packing seals should be checked for damage and
renewed if any leakage is evident.
Critical parts, which should be examined in more detail during routine maintenance, are as follows;
Lance Tube - Check for corrosion, surface damage, and straightness.
Nozzle / Rake Arrg't - Check for cracking and corrosion.
Feed Tube - Check for corrosion, surface damage and straightness.
Carriage – Overheating and noisy running.
Poppet Valve - Dismantle. Valve Stem and Disc Assembly – Check for wear and renew if necessary.
Valve Seat - Check for wear, and lap if necessary. Reassemble using new packing and gaskets.
Ensure that the disc, spring and seat are in good condition.
Air Relief Valve - Pressure Test.
Limit / Proximity Switches - Check for correct operation.
Motor - Check for overheating and freedom of movement.
Major Overhaul
The sootblower should be inspected after a period of long usage for possible renewal of all wearing
parts. If necessary, as a preliminary to this operation, the sootblower should be run and checked for any
malfunctioning.
The procedure for examining critical parts is similar to that given for Routine Maintenance.
5.7 Special Tools

Certain Jobs described in the Maintenance Section can best be accomplished using
The optional, special-purpose tools detailed below:
Manual Wrench – Refer to Section 2.4 for information and procedure.

Lapping Equipment for Poppet Valve – Refer to Section 6.8 for information and procedure.
Poppet Valve Maintenance Tool (Spanner) – Refer to Section 6.7 for information and procedure.
Poppet Valve Maintenance Tool (Depressing Tool) – Refer to Section 6.6 for information and
procedure.
Feed Tube Packing Tool Assembly– Refer to Section 6.2 for information and procedure.

Poppet Valve Tools
1 LAPPING EQUIPMENT FOR POPPET

VALVE
No. Description No. Off
1 Wobble Stick 1
2 Lap Disc, Serrated Face (Series 40) 1

Lap Disc, Serrated Face (Series 60) 1
Lap Disc, Serrated Face (Series 120) 1
3 Lap Disc, Plain Face (Series 40) 1

Lap Disc, Plain Face (Series 60) 1
Lap Disc, Plain Face (Series 120) 1
2
3
1
POPPET VALVE PACKING NUT SPANNER
No Description No. Off
1 Valve Packing Nut Spanner 1
2
AIR RETRACT TOOL
No Description No. Off

1 Air Speed Wrench 1
1
2 22mm Bi-Hex, ½” Drive 1

Feed Tube Packing Tool Assembly
Feed Tube
Feed Tube Packing Tool Assembly - Parts

Item Description Qty
1 Spring Clip 1
2 Body 1
Wrench for Manual Operation
Wrench for Manual Operation - Parts

1 Ratchet Wrench 1
2 Socket Extension 1

5.8 Fault Finding
Symptom Possible Cause Remedy
Sootblower fails to No power: Check power supply.
start. Overload tripped. Check continuity.
Motor fault. Test and rectify circuit.
One power line open: Re-establish continuity.
Overload relay trip due to motor single
phasing.
Contactor fault
Sootblower jams or Drive motor overloaded. Check the orientation of

fails to travel. Lance is fouling in the wallbox. wallbox on the boiler wall.
Lance is fouling on the boiler internals. Adjust the mounting angle of
Dirt or swarf in the wallbox. the sootblower.
Feed tube packing is too tight. Clean the wallbox using
Pipework incorrectly supported stressing the compressed air.
sootblower. Adjust the packing gland.
Carriage Fault Inspect the rack for alignment
and clean the pinion teeth.
Inspect pipework and re-run if
necessary.
Sootblower fails to Limit switch or Proximity Switch fault. Check the trip lever or actuator
stop. operates the switch.
Renew the switch if necessary.
Blowing medium Poppet valve stem is sticking in the guide. Dismantle, inspect and
fails to turn off. Valve yoke is broken or detached from the adjust/renew if faulty.
valve stem.
Valve spring broken.
Valve disc loose on the valve stem.
Operating pin broken.
Cam and pin out of alignment.
Boiler tube Blowing pressure is too high. Re-set to establish

abrasion or baffle Excess moisture is present in blowing medium. recommended blowing
erosion is present Operating cycle frequency incorrect. pressure.
upon internal Blowing area covered is in-correct. Increase temperature of
inspection. blowing medium.
Check frequency of operation.
Check operation of poppet
valve and linkage.
Note
A major cause of IK1M Faults is internal bearing misalignment and/or a misaligned element weld.

6. MAINTENANCE WORKSHEETS
6.1 Pressure Sealing Points – Checking Procedure
A check should be made for leakage at the pressure sealing points listed below. This should be carried
out by operating the sootblower with the blowing medium on. Carry out the following with the sootblower
at rest.
1: Poppet Valve to Companion Flange: Tighten the flange nuts - if leakage persists, renew the gasket.
2: Feed Tube to Poppet Valve: Tighten the Clamp Plate & Bolts - if leakage persists, renew the gasket.
3: Lance Tube: If leakage is detected, tighten the retaining bolts that secure the lance tube flange to the
lance hub. If leakage persists after further tightening, renew the gasket.
Pressure Sealing Points
Item 2: Feed Tube Gasket
Poppet Feed Tube
Valve Item 3:
Stem Lance Tube Gasket
Gland
Locking Plate
Lance
Item 2: Clamp Plate & Bolts Tube
Item 1: Poppet Valve Gasket
Companion Flange
Pressure Sealing Points

Rear Bulkhead
M20 Stud
M20 Hex. Nut
Poppet
Valve
Clamping
Plate
Gasket
M10 Screw
Solid Contact

Note
In Steam Turn-on assembly;
Apply Molykote G-n plus to thread of the M20 Nuts.
Apply Molykote G-n plus to thread of the M10 Bolts.
Feed Tube Packing: Check for leakage. If leakage is detected, tighten the packing gland to eliminate
the leakage. Do not tighten the packing gland more than is necessary as this will shorten the packing life
and increase the load on the motor. If the leakage persists, renew the packing. Slide the packing gland
to the rear of the feed tube. Remove the old packing rings with a flexible hook. Direct the hook at the
bore of the stuffing box to avoid damaging the feed tube.
Carefully clean the carriage hub stuffing box, packing gland and all components. A solvent may be
required to remove all traces of gum.
Inspect the feed tube and stuffing box for scratches, indents or other wear.
Repair or renew any damaged parts.
Feed Tube Packing

Bushing Packing
Flange Gland
Gasket Packing Gland
Poppet Valve Stem Packing
Spring
Poppet Valve
Stem Packing
Packing Nut
Check for leakage. If leakage is detected, tighten the brass packing nut beneath the valve spring by
turning it in a clockwise direction until the leakage has been eliminated, if the leakage persists, renew the
packing

6.2 Feed Tube Packing
Lay out the end and intermediate packing rings in the correct sequence and direction for installation.
(Refer to sketch below)
Slide the rear braided end ring onto the feed tube, pushing it firmly home against the stuffing box
bushing. (Refer to sketch below)
Fit each intermediate ring separately, ensuring at all times that the correct direction of the packing slope
is maintained relative to the front of the sootblower. Push each rings fully home, using the packing
tool, before fitting the next one. Gently press the packing ring into place.
Repeat the procedure with the remaining packing rings.
Index each diagonal cut 90° with the preceding ring.
Insert the last packing ring, and reverse the packing tool, placing the square end towards the stuffing
box. Firmly press the packing ring into position.
Remove the packing tool and slide the packing gland into position.
Split ring packing is used to eliminate the need for removal of the feed tube.
This may initially reduce downtime of the blower but will reduce the timescale between packing
replacement intervals. Ensure that the orientation of the packing is as per drawing detailed below.
The preferred option is the solid ring variant.
The gland should be fully loaded via the loading nut.
Reconnect the power supply.
Test run the sootblower and fully tighten loading nuts.
Feed Tube Packing - Schematic
Lance End
Gland End
Graphite Foil – Install packing in direction
Feed Tube
Packing Tool
Feed Tube
Feed Tube
Packing

6.3 Poppet Valve Maintenance
Note
The Blowing pressure can only be set under normal working conditions, i.e. with blowing medium
available.
Check that the sootblower is in the fully-retracted position.

Check that the poppet valve is in the closed position.
Isolate the poppet valve from the blowing medium supply.
Isolate the sootblower from the power supply
Determine the blowing pressure.
Remove the blanking plug from the equal tee.
Setting the Blowing Pressure
Stem & Disc Spring

Assembly
External Pressure
Gauge
Pressure
Control
Disc
Lock Pin
Plug
Air
Relief
Valve
Plug
Equal
Remove Plug for Connection of Tee
Pressure Gauge
Valve Body
Companion Flange & Gasket Seat
Connect a suitable pressure gauge to the equal tee outlet.

Remove the lock pin plug from the poppet valve and coat the threads with an anti-seize compound,
replace the lock pin.
Turn on the blowing supply.
Open the poppet valve by running the sootblower carriage forward from the “Local/Manual” control
position and note the pressure gauge reading.
Run the sootblower back to the fully retracted position, ensuring that the poppet valve closes.
Remove the lock pin plug.
Using a screwdriver inserted through the lock pin side hole, rotate the pressure control disc to raise or
lower, thus decreasing or increasing the blowing pressure between the valve seat and the valve disc.
Replace the lock pin plug after adjustment has been completed, ensuring that it seats in one of the deep
flutes in the disc.
Repeat earlier steps until the recommended blowing pressure is obtained.
Isolate the poppet valve from the blowing medium supply.
Remove the pressure gauge.
Replace the blanking plug.
Turn on the blowing medium supply.
Reconnect the power supply and test run the sootblower.

6.4 Adjusting Blowing Medium Turn-on Linkage
Note:
Do not operate the blowing medium turn-on linkage by hand with the poppet valve under pressure.
Checking that the cam has been set correctly-see below.
Cam
Trip Stud
Arm Too Short Arm Set Correctly Arm Too Long
Loosen the locking nut and rotate the adjusting rod to increase or decrease the arm length setting
position. Tighten the locking nut when the adjustment is correct.
Steam Turn-on Linkage
Cam Plate
Adjusting Rod
Pivot Block
Locking Nut
Rod End
Poppet Valve
Assembly

6.5 Poppet Valve: Removal from Sootblower
Isolate the sootblower from the power supply to prevent automatic operation of the unit.
Shut off the blowing medium supply.
Disconnect the pipework from the poppet valve to the air relief valve.
Remove the nut, spacer and bolt from the poppet valve trigger assembly.
Remove the yoke cotter pin and withdraw the valve yoke pin from the yoke.
Disconnect the poppet valve at the companion flange.
Remove the bolts from the clamping plate to the rear bulkhead and retain the locking washer.
Pull the feed tube towards the boiler until end of tube is visible.
(Retain the key on the feed tube)
Remove the retaining nuts securing the poppet valve to the clamping plate.
The gasket should be replaced before re-fitting of the poppet valve.
Poppet Valve Removal –View 1
Rear Bulkhead Poppet Valve to Air Relief Valve

Pipework Feed
Tube
Poppet Valve
Clamping Block
Trigger Assembly
Lock Nuts
Poppet Valve
Assembly
Companion Flange
Trigger Shaft
Yoke Pin
Refitting is a reversal of the procedure noted above.

6.6 Poppet Valve Dismantling for Valve Seat Lapping
Poppet Valve Dismantling for Valve Seat Lapping

Trigger
Yoke Pin Valve Spring Yoke
Retainer Cotter Pin
Packing Nut
Valve Spring Packing Valve

Depressing Valve Packing & Valve Stem
Tool Stem Nut Washer
Valve Spring
Retainer
Valve
Stem Packing
Valve Stem
Valve Seat
Remove the poppet valve from the sootblower. (Ref. Section 7.5)
Depress the valve spring just enough to allow removal of the yoke using the Valve Spring Depressing
Tool. Lift off the valve spring retainer and valve spring.
Remove the valve stem and packing washer.
Remove the packing from the stem.

6.7 Poppet Valve Stem Packing Adjustment & Renewal
If leakage occurs at the valve stem at the top of the poppet valve body, the valve stem packing nut may
require tightening, or the valve stem packing may require renewal.
Using the valve packing spanner, turn the brass packing nut beneath the valve spring in a clockwise
direction, tightening just enough to prevent leakage.
Overtightening will shorten the packing life and may cause the valve stem to bind.
The packing nut should torque should be set to a maximum of 80 Nm.
Valve Stem Adjustment & Renewal
Packing Packing Nut
Valve Packing Nut

Spanner
Valve Stem &

Disc Arrangement
Valve Stem Packing Detail
See Note End Ring

Note Below
Setting
See
3 Off
Intermediate
Rings
End Ring Packing Ring Arrangement

Packing Ring Detail
If persistent leakage occurs, and further tightening does not stop it, renew the packing.
Refer to Worksheet for disassembly details of poppet valve packing.

Note
To prevent the valve stem and disc assembly from falling out of the poppet valve, the valve stem should
be supported during this operation. Insert new packing. Use only DPSL standard spares to ensure fit and
sealing compatibility. Seat each ring separately.
Setting Note
This clearance dimension should be set between the bottom face of the packing nut hex and the top face
of the valve stem guide hex. Increasing this dimension above 8mm can cause the spring to hard stop
when the valve is fully open. Decreasing this dimension below 3.5mm may cause problems with the
valve stem packing. Ensure valve stem packing rings are assembled as shown.
CAUTION: Tighten the packing just enough to ensure that the spring is not coil bound when the
valve is fully open. A valve packing spanner, for turning the packing nut, is available for this
operation.
Re-assemble the poppet valve in the reverse order to that given for dismantling.
Note
Valve Stem Guide, Lock Pin and Plug threads to be coated with ‘Molykote Gn Plus’.
Torque Valve Stem Guide to 80Nm (60lb.ft)
6.8 Poppet Valve Tools & Equipment /Lapping the Valve Seat
One disc is serrated, for rough lapping, and the other disc is plain, for finishing and burnishing. The
surfaces of both discs must be kept lapped flat; a lapping machine, or surface plate, can be used to
maintain the disc surfaces.
The tools and equipment required for lapping are as follows:-
Lapping Compounds:-
Diamond Compound, Hyprez 45.
Lapping Equipment:-
Wobble stick, manually-operated valve grinder, or small capacity air motor with flexible shaft.
Inspection Equipment:-
Blue block - for checking flatness. An unused lapping disc, which is absolutely flat, can also be used.
Prussian blue - to determine high and low markings.
Dismantle the poppet valve.
Charge an unused serrated lapping disc with Hyprez 45 compound.
Rough-lap for two five-minute cycles, checking the valve seat surface at the end of each cycle.
Clean off any traces of compound from the seat.
Charge an unused plain lapping disc with Hyprez 14 compound.
Finish lap for two-five minute cycles, checking the valve seat surfaces at the end of each cycle.
Charge the plain lapping disc with Hyprez 3 compound.
Burnish-lap for five minutes.
Cover the surface of a blue block with a very thin uniform coating of Prussian blue.
Place the blue block carefully on the lapped seat.
Applying finger pressure only, move the blue block back and forth slightly.
Carefully remove the blue block.
Inspect the lapped seat.
If the dye transfer is uniform, the seat is satisfactory.
If not uniform, then the seat is not flat and the complete lapping procedure must be repeated.
After the lapping procedure is completed, clean the valve body with white spirit, using a small bristle
brush.
Wobble Stick
Rough Serrated
Disc
Smooth
Serrated Disc

6.9 Poppet Valve – Re-assembly
NOTE
This procedure covers reassembly after partial dismantling for seat-lapping or renewal. The valve should
be reassembled in clean conditions to reduce the possibility of grit being trapped between the sealing
faces.
The reassembly procedure is as follows:
Place the poppet valve on its side.
Install the stem and disc assembly, taking care to ensure that the sealing faces are clean and
undamaged.
NOTE
Maintain firm contact between the sealing faces during the subsequent steps.
Insert the new valve stem packing, staggering the splits in the rings by 90°; seat each ring separately.
Replace the packing washer.
Replace the packing nut and screw it down hand tight only; adjust on assembly.
Place the valve body in an upright position.
Replace the valve spring, valve spring retainer and valve yoke.
NOTE
If the valve is not to be put into service immediately, the inlet and outlet should be sealed to protect the
internal components.
Replace the poppet valve on the sootblower.
Poppet Valve Re-assembly
Rear Bulkhead
Gasket
Poppet Valve Clamping Plate

Circlip
Feed Tube Key
Feed Tube
M10 x 35Lg Hex Bolts / Washers (Hidden)

M20 Nut

6.10 Poppet Valve – Replacing on the Sootblower
Ensure that the sootblower is isolated from the power supply and that the blowing medium supply is shut
off.
Ensure that the valve inlet and outlet sealing surfaces are clean and undamaged.
Fit a new feed tube gasket to the valve outlet flange.
Position the poppet valve on the sootblower with the four studs projecting through the mounting plate
assembly.
Poppet Valve Renewal
Trigger Shaft Adjusting Rod

Arrangement
Cam
Assembly
Trip Pin
Securing Studs, Washers & Nuts

Companion Flange Gasket
The feed tube retaining ring groove should be clean and the edges free from burrs.
Ensure that the retaining ring is fully seated in the groove with the sharpest edge of the retaining ring
installed towards the mounting plate assembly.
Push the feed tube through the mounting plate. The 5mm key in the tube should be aligned with the key
slot in the mounting plate and inserted until the tube end makes contact with the feed tube gasket.
Slide the feed tube clamping plate along the feed tube ensuring that the counter bore in the clamping
plate engages squarely over the retaining ring.
Loosely fit the locking washers and securing nuts which retain the poppet valve to the mounting and
clamping plate assembly.
Locate and tighten the two screws of the clamping plate in turn by torquing them in small increments to
41Nm maximum. This procedure will ensure that the clamping plate is pulled squarely on to the retaining
ring compressing the feed gasket between the poppet valve and the end of the feed tube.
Tighten the poppet valve locking washers and securing nuts in turn by torquing them in small increments
to 75Nm maximum. For each nut, bend up only one tab of the locking washer.
Re-connect the poppet valve trigger to the yoke with the pin and cotter pin.
Fit a new companion flange gasket.
Re-connect the companion flange to the poppet valve.
Re-connect the scavenging air line to the air relief valve.
Re-connect the blowing medium and power supply.
Test-run the sootblower, checking for leaks.
Reset the blowing pressure.

Rod End Assembly
Pivot Pin
Washer
Circlip
Pivot Block
Cam M12 x 30
Spacer
Rod End
Circlip Pivot Pin
Screw the adjusting rod fully into each ball joint - LH thread on the cam one.
Attach the ball joint to the PV trigger, using spacers etc.
Adjust the cam angle by turning the rod. (Refer to Adjustment Blowing Medium Turn-On Linkage
section.)
Lock the rod position with the M16 nut.

6.11 Lance Tube / Gasket – Adjusting & Removal Procedure
The lance tube is welded onto a mounting flange. The lance assembly is attached to the lance hub and a
gasket is compressed between the lance hub and the lance tube flange by tightening the retaining bolts
in the sequence shown in the illustration below. Ensure that a gap exists between the hub flange and
lance neck flange to provide a proper gasket seal. The bolt torque should be set to 23Nm.
Lance Tube Gasket
1 3
Carriage
Chassis
6 5
Key
Circlip
Flange 4 2
Lance Assembly
Assembly
Packing
Gland
Feed Tube
Gasket
Lance Hub Bushing Feed Tube Packing
Note
The torque figure given applies to new bolts coated with anti-seize compound. Higher torque may be
necessary when re-tightening in service.
If persistent leakage occurs and further tightening does not stop it, renew the gasket.
Renewal of Lance Tube Gasket:

Ensure that the carriage is in the fully-retracted position.
Isolate the sootblower from the power supply.
Remove the four nuts which secure the poppet valve to the rear bulkhead; remove the poppet valve.
Remove the feed tube retaining ring.
Slide the feed tube to the rear of the sootblower, ensuring that the feed tube and lance tube are
supported securely.
Remove the six bolts and lockwashers which secure the lance tube flange to the lance hub flange.
Move the lance tube forward far enough to clear the carriage hub.
Remove the existing lance tube flange gasket.
Examine the locating face at the lance hub and lance tube flange.
Clean and remove any loose particles of dirt or existing gasket, as applicable.
Fit the new gasket.
Reassemble in the reverse order to that given for dismantling.
NOTE
Coat the threads of the six lance hub flange bolts with anti-seize compound before re-assembly, and
torque to 23 Nm.

Lance and Feed Tube - Removal:
Remove one of the front support rollers.
Move the carriage forward manually to obtain sufficient access to feed tube clamping bolts and nuts.
Remove the four nuts which clamp the feed tube to the poppet valve via the mounting plate and slide the
clamping plate forward.
Remove the feed tube retaining ring.
Push the feed tube forward and remove the clamping plate.
Disconnect the air relief valve from the scavenging air line.
Remove and aside the poppet valve assembly
Withdraw the feed tube via the rear bulkhead plate.
Support the lance tube.
Remove the six bolts and lockwashers from the lance hub flange.
Withdraw the lance tube via the rear bulkhead plate.
Inspect the lance and feed tube, repair or renew as required.
Re-assembly is a reversal of the removal instructions.
NOTE
Coat the threads of the six lance hub flange bolts with anti-seize compound before reassembly, and
torque to 23 Nm.
The torque figure given applies to bolts coated with anti-seize compound. Higher torque may be
necessary when re-tightening in service.
Re-connect the blowing medium supply.
Re-connect the power supply.

6.12 Removal of Carriage from Sootblower
Ensure that the carriage is in the fully retracted position.
Isolate the sootblower from the blowing medium and power supply.
Disconnect the power supply cable from the motor.
Remove the cover plate, screws and lockwashers from the access hole on the top of the beam.
Support the carriage by a hoist attached through the access hole.
Support the lance tube by slinging or blocking from the underside of the beam.
Disconnect the lance and feed tubes and slide the feed tube forward to expose the feed tube retaining
ring. Remove the retaining ring, key and clamping plate.
Slide the feed tube through the gland and into the lance tube
Remove the cotter pins at the rear bulkhead and withdraw the guide tube and guide block assembly.
Remove the grub screw securing the leadscrew collar and withdraw the leadscrew by unscrewing it
through the carriage drive nut.
Disconnect the four nuts which secure the feed tube clamping plate to the poppet valve.
Slide the feed tube forward to expose the feed tube retaining ring.
Remove the feed tube retaining ring, key and clamping plate.
Slide the feed tube through the gland and into the lance tube.
Disconnect the six screws which secure the lance to the carriage.
Slide the lance and feed tube forward to clear the carriage.
Lower the carriage onto the gantry.
Remove the carriage to the bench for inspection and overhaul.
Re-assemble in the reverse order to that given for removal.
Re-connect the power supply cable to the motor.
Re-connect the blowing medium and power supply.
Removal of Carriage
Cotter Cover Plate

Pin Carriage Leadscrew
Drive Nut Collar
Drive
Motor
Terminal Box
Feed Tube
Clamping Plate
Carriage Assembly
Lance Tube Assembly

6.13 Carriage Dismantling: Drive Pinion & Worm Gear
Remove the four screws and lockwashers which secure the motor to the housing. Save the screws for
re-use, but discard the lockwashers. Withdraw the motor; save the collar and the key for re-use.
Remove and discard the expansion plug and the circlip; withdraw the worm shaft.
NOTE
To avoid damage to the worm gear, ensure that it is free to rotate as the worm is withdrawn.
Remove the chain guard and chain (if fitted).
Remove the eight screws and lockwashers which secure the bearing carrier to the housing and withdraw
the bearing carrier complete with its bearing; save the gaskets for re-use.
Withdraw the drive nut complete with its bearing and worm wheel; the worm wheel and drive nut can
now be examined and renewed if necessary.
Remove the bearing from the carrier for examination and or replacement, as required. The seal should
be discarded.
Remove the retaining ring and pull off the flange.
Remove the retaining ring at the front end of the lance hub, and withdraw the lance hub, complete with
the hub and the bearing, from the carriage housing.
Remove the retaining ring which secures the hub and bearing to the lance hub; the bearing can now be
removed from the lance hub for examination.
Examine the guide nuts and renew if necessary.
Drive Pinion & Worm Gear

Gasket
Key Seal
Bearing Carrier
Motor Mounting Screw

Trip Pin & Lockwasher
Worm Wheel Key Leadscrew Drive Nut
Bearing
Key
Support Bearing
Expansion Plug
Circlip
Retaining Ring
Worm Shaft
Lance Hub

Re-assembly:
Before re-assembly, all parts should be cleaned and examined for wear or damage. New oil seals,
expansion plugs, and lockwashers should be used. The worm gear cavity should be packed with grease
as specified in the lubrication chart.
The procedure to be adopted is generally the reverse of that used in dismantling but, if a new worm gear
or drive nut is fitted, the drive nut end play relative to the housing must be checked to ensure that it is
within the limits, 0.127 mm to 0.508mm. The end play can be varied by adjusting the gasket thickness
between the bearing carrier and the housing. Gaskets are available in two thicknesses, 0.381 mm and
0,787 mm.
Carriage – Notes on Major Overhaul

1. Assemble worm wheel, nut, bearings and bearing carrier. Measure gap between housing and bearing
carrier. Shim to give 0.13mm – 0.51mm end play.
2. Pack worm set with 385-400g of lubricant defined within lubrication section. Lubricant should be filled
from front trip pin hole to ensure that worm gear is lubricated.
3. Torque screw, detail 30 in Carriage Assembly Sheet, to 5.6 Nm; torque pattern one time around only.
4. Chain guard is not required on non-rotators, or when bottom (beam) guard is specified.
5. Loctite 572 thread sealant to be applied to all taper threads.
6. Expansion plug & motor flange gasket to be fitted with 744 Dow Corning silicone adhesive sealant.
7. The locking assembly should be set in the unlocked position for normal duty. For hand operation,
loosen the M6 screws, raise the locking assembly 10mm to the locked position, so that the lock is
engaged with the 18T sprocket and tighten the screws.
NOTE
After reassembly, test-run and check for noise and leaks.

6.14 Wallbox Dismantling / Replacement
Wallbox replacement should not be necessary during normal usage. However during a major overhaul,
after several years’ operation, individual component parts showing excessive wear may be replaced.
As this operation requires the cutting of the element from the lance and a subsequent re-welding
process, application should be made to Diamond Power for supply of an appropriate Technical Data
sheet that details the remedial action required.
Isolate the sootblower from the blowing medium and power supply to prevent automatic operation of the
unit. Ensure that the carriage is in the fully retracted position.
Attach a sling around the lifting lugs at the front and rear of the sootblower.
Remove the four nuts, washers and bolts which attaches the welded wallsleeve and flange to the
sootblower.
Reposition the sootblower to separate it from the wallsleeve and flange arrangement.
Remove the seal plate from the wallbox.
Check that there is enough slack on the control and power cables to allow the sootblower to be pulled
back until the lance is clear of the wallbox. If not, it may be necessary to disconnect the cables at the
sootblower terminal box. Slacken or remove the four seal plate adjusting screws.
Re-assemble the wallbox using existing / new parts as follows;
Reassemble the seal plates to the wallbox with the machined face of the front seal plate towards the
wallbox flange. Apply Dow corning 744 silicone sealant to the faces of the wallbox housing.
When the M12 mounting bolts are tightened the wallbox seal plates must be adjusted to give the correct
clearance by turning the four (4) M10 seal plate adjusting screws clockwise until there is no seal plate
movement. Turn each screw counter-clockwise by I flat (1/6th turn). Check that the seal plates are free
to move.
Wallbox Dismantling / Replacement – Positive Pressure
Wallbox
Front Bulkhead
Lance Front Roller Assembly
Wallbox Renewal – Positive Pressure

Disconnect the sealing air supply from the wallbox.
Remove the weld between the wallbox and the wallsleeve
Remove the wallbox housing.
Position and weld a replacement wallbox to the wallsleeve.
Re-install the sootblower in the reverse order to that given
Reconnect the sealing air supply to the wallbox.
Turn on the blowing medium supply. Reconnect the power supply.

6.15 Limit Switches – Renewal & Adjustment
Renewal
Unscrew the cable gland and connecting cable from the faulty limit switch, noting the correct wire
termination points.
Remove the two mounting screws and lockwashers which secure the faulty limit switch to the beam, via
the mounting rail assembly; remove the complete limit switch from the rail.
Select a new limit switch and install it in the reverse order to that given for removal; ensure that the wires
are fitted to the same termination points.
Limit Switch Assembly
Screw – Washers
Face Nut
Mounting Rail
Limit Switch
Cable Gland
Mounting Screws
Adjustment Procedure
Check that the contact roller engages correctly with the carriage. The angular position of the roller crank
can be altered by loosening the adjustment screw.
The limit switch position can also be adjusted by slackening the fixing screws on the mounting rail and
sliding the whole assembly in the direction of the adjustment required. Re-tighten after adjustment.
Operate the sootblower manually to check that the limit switches operate correctly when tripped by the
carriage.
Turn on the blowing medium supply.

7. PARTS IDENTIFICATION
The correct part names for spares ordering can be identified by referring to the following assemblies.
Please quote:-
• DPSL Contract Number.

• Sootblower Serial Number.
• Sootblower Position Number.
• Figure Number, Item Number and Page Number from this manual.
A recommended spares list can be supplied on request.
Contact D.P.S.L. Spares Department

Telephone +44 (0) 1389 727900
Fax +44 (0) 1389 757405
IK1M – Standard Sub Assemblies Drawing No.
IK1M-TE (EMD) Main Assembly 398742-0043
Carriage Assembly N1148512-C018
Electrical Control Assembly – Limit Switch Assembly N11485-C100
Lance Joint and Packing Assembly 395608-4044
Blowing Medium (Steam Turn-On Assembly) N1148514-C005
Poppet Valve Assembly N1148514-C019
Wallbox & Scavenge Line Assembly N1148514-C007
Air Relief Valve Assembly N1148512-C023
Fold Flat Guard Assembly N11485-GUARD
Rear Cover Assembly – Acoustic Cover Assembly N1148512-C006
Regulating Valve Assembly N1148512-C008
Front Roller Assembly N1148512-C015
Front Roller Wheel Assembly 395635-1039
Limit Switch Trip Assembly – Part of Control Assembly N11485-C100
Rear Support Assembly N1148512-C017
Seal Air Skid Fan N11485-4-3
Carriage Motor & Guide Assembly N1148512-C018

7.1 IK1M Sootblower Main Assembly
24 12-15
22-23
7
25
26-27
14
18
16 11
1
17
32 5
12
29-30
15
33
10
3 2 4 9
28
13

IK1M Sootblower - Main Assembly - Parts
1 Beam Assembly 1
2 Carriage Assembly 1
3 Feed Tube Assembly 1
4 Lance Tube Assembly 1
5 Steam Turn-On Assembly 1
6 Leadscrew 1
7 Guide Assembly 1
8 Electric Control Assembly 1
9 Mounting Flange Wallbox Assembly 1
10 Front Roller Assembly 1
11 Air relief Valve Assembly 1
12 Locating Collar Leadscrew 1
13 Lance Joint & Packing Assembly 1
14 Split Cotter Pin 1
15 Locating Collar Leadscrew 1
16 Locking Pin Leadscrew 1
17 Roll Pin 1
18 Emblem 2
19 Warning Tag 2
20 Nameplate 1
21 Gripnail, Amtex 4
22 Hex. Hd. Screw 2
23 Lockwasher, Split Type 2
24 Top Cover Plate 1
25 Leadscrew Clamp Assembly 1
26 Hex. Hd. Bolt 1
27 Nylock Nut 1
28 Bolt-On Bulkhead Assembly 1
29 Companion Flange Assembly 1
30 Companion Flange Gasket (Not Illustrated) 1
31 Guard Assembly (Not Illustrated) 1
32 Rear Support Assembly 1
33 Scavenging Air Assembly 1

7.2 Carriage Assembly - Standard 22
5
12
11 6
13
14
44
17
23
Unlocked Position
34 1
33
Locked Position
20
18 - 19
10 3-4 2 29 28
26
30
21
24
27
9
44
31
32
9 25
Carriage Assembly - Parts
1 Housing 1
2 Bearing Carrier 1
3 Gasket Bearing Carrier 1
4 Gasket Bearing Carrier As Reqd
5 Gasket Motor Flange 1
6 Collar, Motor Shaft 1
7 Key 1
8 Retaining Ring 2
9 Ball Bearing 2
10 Ball Bearing 2
11 Ball Bearing 1
12 Retaining Ring 2
13 Retaining Ring 1
14 Expansion Plug 1
15 Hex. Head Screw 4
16 Lockwasher 4
17 Key 1
19 Lockwasher 8
20 Key 1
21 Seal 1
22 Worm Gear 1
23 Worm Shaft 1
24 Drive Nut 1
25 Sprocket Arrangement 1
26 Sprocket 18T 1
27 Chain Arrangement 1
28 Locking Plate 1
29 Screw 2
31 Hub, Sprocket 1
32 Lance Hub 1
33 Trip Pin 1
34 Pipe Plug As Reqd
35 Hub Arrangement 1
36 Rotary Union 1
37 Nipple 1
38 Equal Elbow 1
39 Torque Bracket Arrangement 1
40 Lubrication As Reqd
41 Chain Guard Arrangement 1
42 Plain Washer, M6 2
43 Socket Head Screw 2
44 Locking Assembly 1
45 Locking Assembly, IK1M Selective Pattern 1

7.3 Electrical Control Assembly- Limit Switch Arrg’t
Rear Limit
Switch
Front Limit
Intermediate Switch
Limit Switch
Terminal Box
Motor Assembly
Limit
Switch 4
7-8
Cable
1-2-3
3-5-7-8
Push-in Blade The single face rail nut may be

To Remove push fitted into the mounting rail
3 over the L/S cable.
6 Removal may be achieved by

Cable levering out with a flat bladed
screwdriver BUT care must be
taken not to pinch damage the L/S
cable.

Control Assy - Parts
Description Qty
1 M5 x 0.8 x 16 Lg. Hex. Soc. Hd. Screw, 304SS 3

2 M5 Lockwasher, Split Type, 304SS 3
3 M5 x 0.8 Rail Nut, Twin Face 9
4 Cable Clip Norma 1
5 M8 Washer, Form C, HDG 6
6 Mounting Rail (1500 Travel) 1
7 Washer, Serrated, M5, 304SS 6
8 Screw, M5, 304SS, Refer W/D for length etc. 6

7.4 Lance Joint & Packing Assembly
7
1
6
9 4
12 - 13
11
5
2 3
10

Lance Joint & Packing Assembly – Parts
Description Qty
1 Key 1
2 Flange Hub 1
3 Retaining Ring 2
4 Gasket, Lance Tube 1
5 Front Bushing 1
6 M10 x 1.5 Hex. Nut 1
7 M10 x 1.5 Hex. Locknut 1
8 M10 Washer , Form-A 1
9 Stud Gland Packing 1
10 Packing, Feed Tube, Graphoil, Split Ring 2
10 Packing, Feed Tube, Teflon, Split Ring 2
10 Packing, Feed Tube, Solid Graphoil & Yarn 4-6
11 Packing Gland Assembly 6
12 M10 Lockwasher, Split Type 2
13 M10 x 1.5 x 45 Lg. Hex. Hd. Screw 4
Note: Torque all screws to 23 Nm. Apply Molykote GN plus to threads and heads.
1. Torque screws to 23 Nm.
2. Apply Molykote Gn Plus to heads and threads.
3. In any maintenance breakdown the machined face of the flange should face the lance on re-
assembly.

7.5 Steam Turn-On Assembly
2 19
7
15
20 38
14 37
21
3
5
10
28 36
8-9
8 - 9 -12 - 31
29 - 30
22
Air Relief Valve Assy
26 17
27 25
39 18
28 Rear Bulkhead
40
11 – 12 -13 5
35
32 - 33
4
23
21
18 24 16
23 34

Steam Turn-On Assembly – Parts
Description Qty
1 Rod End 1
2 Rod End 1
3 Washer 1
4 Cam Assembly 1
5 Mounting Assembly, Poppet Valve IK1M 1
6 Oilite Bearing 2
7 Spacer, Poppet Valve Trigger 1
8 M12 x 1.75 x 60 Lg. Hex. Hd. Bolt 4
9 M12 Washer, Form -C 8
10 Ø5 x 35 Lg. Roll Pin 2
11 M12 Washer, Form -A 2
13 M12 x 45 Lg. Hex. Hd. Screw 3
14 Trigger Shaft Assembly, Metric 1
15 M16 x 2.0 Aerotight Hex. Nut. 1
16 Bearing retainer, Poppet Valve Mounting 1
17 Pivot Block Assembly 1
18 Washer 2
19 Spacer, Poppet Valve Trigger 1
20 M16 x 2.0 x 90 Lg. Hex Bolt 1
21 M16 Washer, Form - A 1
22 M16 x 2.0 Hex. Nut 1
23 Spacer, Poppet Valve Cam 1
24 External Retaining Ring 1
26 Gasket, Feed Tube 1
28 Feed Tube Clamping Plate 1
30 M10 x 1.5 x 35 Lg. Hex. Hd. Screw 2
31 M12 x 1.75 Hex. Hd. Nut 4
32 Pin, Poppet Valve Yoke 1
33 Ø2 x 15 Split Cotter Pin 1
34 M6 x 1.0 x 16 Lg Hex. Soc. Hd. Screw 3
35 Ø8 x 70 Lg. Roll Pin 1
36 M10 x 1.5 x 10 Lg. Hex. Soc. Hd. Cup Point Grub Screw 4
37 Plate, Lead Screw Locking Bracket 1
38 Block, Lead Screw Locking 1
39 Key 1
40 Adjusting Rod 1
Notes
Apply Molykote Gn + to thread and faces of Poppet valve Nuts and torque to 75Nm.
Apply Molykote Gn + to threads and head of Screws and torque to 41Nm.
Assemble all threads with Molykote Gn +.
Assemble Rod Ends with Molykote Gn + plus on the bores.
When valve is fully open, ensure there is a minimum gap of 0.25mm between spring coils.

7.6 Blowing Medium – (Steam Turn-On Assembly)
1. In any maintenance programme re-assemble the adjusting rod ends with equal thread
engagement at each end. For reference, the nominal engagement will be 23mm.
2. Adjustment at final assembly is achieved by loosening the locking nuts and rotating the adjusting
rod. Re-tighten the locking nut when adjustment is correct.
3. Apply Molykote Gn+ to threads and heads of screws and torque to 41Nm.
4. Apply Molykote Gn+ to threads and faces of poppet valve nuts and torque to 75Nm.
5. Foe each nut, bend up only ONE tab of the locking washer.
6. Apply Molykote Gn+ to all threads before assembly.
7. Assemble rod ends with Molykote Gn+ on the bores.
8. When the valve is fully open, ensure that there is a minimum gap of 0.25 between the valve
spring coils.
9. Install Oilite bearing flush with the inside surface of Poppet Valve Mounting.
10. Install Oilite bearing flush with the small diameter face of bearing retainer.
11. The trigger assembly should be fitted by inserting the non-lever end through the larger hole in
the poppet valve mounting bracket. Fit a washer before inserting the lever end into the oilite
bearing within the smaller hole of the poppet valve mounting bracket. Finally fit the bearing
retainer complete with oilite bearing.
12. When the valve is fully open ensure that there is a minimum gap of 0.25mm between valve
spring coils.
Trigger
Lever
Mounting
Bracket
Trigger Washer Oilite
Assembly Bearing

7.7 Poppet Valve Assembly
15
17
20 16 18
4 19
12
2 11
1 3
13
14
26
25 23
22
Air Relief Valve Connection

Poppet Valve Assembly – Parts
Item Description Qty.
1 Valve Body 1
2 Valve Stem & Disc Assy 1
3 Flexible Valve Seat 1
4 Pressure Control Disc 1
5 - 10 Not Applicable 1
11 Lock Pin Plug 1
12 Copper Washer 1
13 Valve Yoke 1
14 Valve Spring Retainer 1
15 Valve Spring 1
16 Packing Nut 1
17 Packing Washer 1
18 Valve Stem Packing 1
19 Valve Stem Guide 1
20 Valve Stem Washer 1
21 Adjusting Pressure Tag (Not Shown) 1
22 Nut 4
23 Stud 4
24 Not Applicable 1
25 Locking |Washer, Poppet Valve Nut 2
26 Plug, G3/4 1
Notes
Valve Stem Guide, Lock Pin and Plug threads to be coated with ‘Molykote Gn Plus’
Torque Valve Stem Guide to 80Nm (60lb.ft)
1. Valve stem guide, Lockpin, Adaptor and Plug threads to be coated with Molykote Gn+.
2. Torque Valve stem guide to 80Nm.
3. A clearance dimension should be set between the bottom face of the packing nut and the top
face of the valve stem guide hex. Increasing this dimension above 8mm can cause the spring to
hard stop when the valve is fully open. Decreasing this dimension below3.5mm may cause
problems with the valve stem packing.
4. Due to the assembly process, Valve Body, Valve Seat, Pressure Control disc and Flange
adaptor (Spares only) are now assembled and welded as a sub assembly.

7.8 Wallbox Assembly – Scavenge Line Assembly – Positive Press.
11 16 17 12-13
11
10 1
9
15
14
6-7-8 7-8-24
22 17 18
6-7-8
19-20-21
3 2
17 Air Relief Valve
Assembly
5 23

Wallbox Assembly – Scavenge Line Assembly –Positive Pressure – Parts
Item Description Qty.
1 Wallbox Housing 1
2 Seal Plate 1
3 Seal Plate Assembly 1
4 Wallbox Flange 1
5 Hex. Hd. Screw 4
6 Hex. Hd. Bolt 4
7 Hex. Nut 12
9 Reducing Tee 1
10 Hose Tail 1
11 Hose Clip 2
12 Elbow Hose Tail 1
13 Adaptor 1
14 Nipple 1
15 Plug 1
16 Rubber Hose A/R
17 Scavenge Line Copper Tube A/R
18 Clamp, Copper Tube 1
19 Hex. Nut 1
21 Hex. Hd. Screw 1
22 Elbow 1
23 Roll Pin 1
24 Hex. Hd. Screw 4
1. At assembly, apply Hylomar sealant to the periphery of the cover plate and the bore of the
housing adjacent to the cover plate and the retaining pin groove. Remove excess sealant after
assembly.
2. The housing and test plug can be supplied as individual parts, complete wallbox assemblies can
also be supplied.
3. After welding the wallbox to it’s wallsleeve, the seal plate clearance must be set to 0.25 –
0.38mm, as follows:
(a) Turn the four screws clockwise until there is no seal plate movement.
(b) Turn the screws counter-clockwise by I flat (60°)
(c) Check that the seal plates are free to move.
(d) Failure to do this will result in damage to the lance and seal plates.

7.9 Air Relief Valve – Positive Pressure
4-5
6
9
7
Air Relief Valve - Parts

1 Nipple 3/4" NPT x 70 Lg. 1
2 Nipple 3/4" NPT x 95 Lg. 1
3 Air Relief Valve Assy, 3/4" NPT 1
4 Adapter, G3/4 - 3/4" NPT 1
5 G3/4 Copper Washer 1
6 Tee, 3/4" NPT, 3000# 1
7 Adapter, 3/8" NPT - 3/4" NPT 1
8 C.S. Elbow, 20mm O/D Tube x 3/4" BSPT Male Stud 1
9 Plug 3/8" NPT 1
10 Adj. Pressure Control Tag – Not Shown 1

7.10 Fold Flat Guard Assembly
Beam Shell
4
Accoustic Fold Flat Guard
Cover
3
5-6
4
7
5-6
1 7
4
1
5-6
8
8
2

Fold Flat Guard Assembly – Parts
1 Fold Flat Panel Guard, Hinged 2
2 Bracket-Guard Fixing 8
3 Screw Retaining Washer M8 8
4 M8x16 Hex. Hd. Screw 8.8 Hdg 24
5 M8 Form C Washer Hdg 24
6 M8 Lockwasher Spring Type Hdg 8
7 M8 Cage Nut 16
8 Rear Cover Assy 1
1. IK1M Guarding consists of a standard length guard assembly and, if required, a variable length
guard assembly.
2. All assemblies may be folded flat for transportation.
3. Rear cover guards are attached to the beam shell.

7.11 Rear Cover Assembly – Acoustic Cover
Beam Shell
Rear Bulkhead
2 3-4-5-7 3-4-6-7

Acoustic Cover Guard Assembly – Parts
1 Cover, Upper, Acoustic IK1M, Pre-galv 1
2 Cover, Lower, Acoustic IK1M, Pre-galv 1
3 M8 Washer, Form-C, HDG 8
4 M8 Lockwasher, Split Type, HDG 8
5 M8 x 1.25 x 16 Lg. Hex. Hd. Screw, HDG 2
6 M8 x 1.25 x 35 Lg. Hex. Hd. Screw, HDG 6
7 Screw Retaining Washer M8 16
1. Fit lower cover (Item 2) before fitting the upper cover (Item 1) as shown.

7.12 Front Roller Assembly
Front Roller Assembly – Parts

1 Front Bulkhead Assy, Bolt-on 1
2 Front Roller Assy 2
3 Retaining Ring 2

7.13 Front Roller Wheel Assembly
1 2
Front Roller Wheel Assembly – Parts
Description Qty
1 Roller 1
2 Ball Bearing 1
3 Retaining Ring 2

7.14 Limit Switch Trip Assembly
4-6 7 4-6
3
3
4
7 1 5
Limit Switch Trip Assembly – (Rear Assembly Shown)
Limit Switch Trip Assembly – Parts

1 Limit Switch 1
2 Mounting Rail 1
3 Square Nut – (Per Assembly) 4
4 M5 Washer Form C – (Per Assembly) 2
5 M5 x 40 Cap Screw – (Per Assembly) 4
6 M5 x 20 Cap Screw – (Per Assembly) 2
7 M8 Form-C Washer 2

7.15 Rear Support Assembly
Cover Plate
3-4 Rear Support

Lug
Integral with Side
Plate
2
5-6
Rear Support – Parts

1 Rear Support Bar 1

2 Screwed Rod 2
3 Hex Nut 4
4 Washer 4
5 Cotter Pin 2
6 Plain Washer 2

7.16 Carriage – Motor & Guide Block Sub Assembly
4-5
4-5
Rear Support – Parts

1 IK1M Motor 1
2 IK1M Carriage 10 H/T Rot Std N/G R 1
3 Guide Block Assembly, IK1M 1
4 M10 x 1.5 - 25 lg. Hex Hed Screw 2
6 Ø10x24 Roll Pin 2

Pp10 CCGT Power Station: Sootblower Operation and Maintenance Manual

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3 Update PS GS 18/Apr/2013

0 FIRST ISSUE PS GS 11/May/2012

REV DESCRIPTION PREP CHKD CHKD APPD DATE

PP10 CCGT POWER STATION

Sootblower Operation and Maintenance Manual

COMPANY/ORIGINATOR: PROJECT DOCUMENT NUMBER: REV.

Rev 1.0 Page 1 of 78

Diamond Power Specialty Limited

Tel: Dumbarton +44 (0)1389 727900

Rev 1.0 Page 3 of 78

 +44 1389 727 900

 Diamond Power Speciality Ltd

ELECTRICAL SAFETY WARNING

Rev 1.0 Page 4 of 78

Rev 1.0 Page 5 of 78

Rev 1.0 Page 6 of 78

1.1 CONTRACT IDENTIFICATION

Diamond Contract No. N11485

Position No. Serial No. Unit No. Tag No.

For Information Refer to

Customer Order No.

HEAD PRESSURE SETTINGS AND CORRESPONDING FLOWS ARE

Rev Description Date By

Rev 1.0 Page 7 of 78

2.2 Sootblower Identification

2.3 Operating Cycle

Rev 1.0 Page 8 of 78

IMPORTANT SAFETY NOTICE:

View on Rear Bulkhead Assembly

Rev 1.0 Page 9 of 78

Locked Position Un-locked Position

Rev 1.0 Page 10 of 78

Keep clear and be aware of the following:-

Do not operate the sootblower locally unless permitted to do so.

2.6 Cleaning Principle

Typical Nozzle Cleaning Pattern

Travelling Element – Rotating

Rev 1.0 Page 11 of 78

Main Assembly Components

Rear Support Assembly

Air Relief Valve

Front Bulkhead Positive Wallbox

Rev 1.0 Page 12 of 78

Front Lifting Point

3.3 Front Roller Support Assembly

Lance Tube Bulkhead Assembly

Rev 1.0 Page 13 of 78

Positive Pressure Wallbox

Scavenge Air Pipe &

Hex Seal Plate

3.5 Pressure Regulating Valve

Rev 1.0 Page 14 of 78

Cam Mounting Plate

Rear Support Bar Integral Support Lugs

3.7 Carriage & Drive Mechanism

Carriage & Square Shaft Drive Assembly

Drive Sprocket Stationary

Lance Hub Worm Shaft Drive Motor

Rev 1.0 Page 15 of 78