Boiler & Auxiliaries Maintenance Manuall Qn1 Sec G 04 TP 009

SEC
QUANG NI NH THERMAL POWER J OI NT STOCK COMPANY

2300 MW
BOI LER & AUXI LI ARI ES MAI NTENANCE MANUAL

Date: 2008-10-20 No.:QN1-SEC-G-04-TP-009
Rev. : A

QUANG NINH THERMAL POWER JOINT STOCK COMPANY
2 300 MW Anthracite Coal Fired Power Station

BOILER & AUXILIARIES

Maintenance Manual

SEC
2300 MW

Date: 2008-10-20 No.:QN1-SEC-G-04-TP-009 - 1 -
Rev. : A

INDEX

1 MAI N TECHNICAL SPECI FI CATI ONS AND STRUCTURE OF BOI LER ( TAKI NG
SG-995/17.3-MMX BOI LER AS EXAMPLE)................................................................................................- 1 -
1.1 GENERAL ................................................................................................................................................... - 1 -
1.2 TECHNICAL SPECIFICATION OF THE BOILER ............................................................................................... - 1 -
1.3 BOILER STRUCTURE................................................................................................................................... - 2 -
2 BOI LER PROPER.........................................................................................................................................- 4 -
2.1 DRUM ........................................................................................................................................................ - 4 -
2.1.1 SPECIFICATION OF DRUM......................................................................................................................... - 4 -
2.1.2 EQUIPMENT INSIDE THE DRUM ................................................................................................................ - 4 -
2.1.3 DRUM MAINTENANCE INSPECTION.......................................................................................................... - 4 -
2.2 LOWER DRUM............................................................................................................................................ - 9 -
2.2.1 LOWER DRUM TECHNICAL SPECIFICATION............................................................................................... - 9 -
2.2.2 MAINTENANCE OF LOWER DRUM ............................................................................................................ - 9 -
2.3 WATER WALL ........................................................................................................................................... - 11 -
2.3.1 TECHNICAL SPECIFICATION OF WATER WALL, STEAM-WATER CONNECTION PIPE, WATER WALL HEADER. - 11 -
2.3.2 MAINTENANCE OF WATER WALL AND HEADER....................................................................................... - 11 -
2.4 SUPERHEATER, REHEATER AND HEADER.................................................................................................. - 14 -
2.4.1 SPECIFICATION AND STRUCTURE OF SUPERHEATER AND REHEATER....................................................... - 14 -
2.4.2 MAINTENANCE OF CONVECTION SUPERHEATER .................................................................................... - 19 -
2.4.3 MAINTENANCE OF PLATEN SUPERHEATER............................................................................................. - 23 -
2.4.4 MAINTENANCE OF FURNACE TOP AND ENCLOSURE SUPERHEATER......................................................... - 23 -
2.4.5 MAINTENANCE OF CONVECTION REHEATER.......................................................................................... - 23 -
2.4.6 MAINTENANCE OF RADIANT REHEATER................................................................................................. - 28 -
2.4.7 MAINTENANCE OF PLATEN REHEATER................................................................................................... - 28 -
2.4.8 MAINTENANCE OF HEADER................................................................................................................... - 28 -
2.5 ECONOMIZER........................................................................................................................................... - 29 -
2.5.1 TECHNICAL SPECIFICATION OF ECONOMIZER TUBE, ECONOMIZER HEADER............................................ - 29 -
2.5.2 MAINTENANCE OF ECONOMIZER........................................................................................................... - 29 -
2.6 BURNER................................................................................................................................................... - 33 -
2.6.1 TECHNICAL SPECIFICATION OF BURNER................................................................................................. - 33 -
2.6.2 MAINTENANCE OF BURNER................................................................................................................... - 33 -
2.7 ROTARY AIR PREHEATER.......................................................................................................................... - 34 -
2.7.1 TECHNICAL SPECIFICATION OF ROTARY AIR PREHEATER ........................................................................ - 34 -
2.7.2 MAINTENANCE OF ROTARY AIR PREHEATER .......................................................................................... - 35 -
2.8 DESUPERHEATER...................................................................................................................................... - 56 -
2.8.1 TECHNICAL SPECIFICATION OF DESUPERHEATER ................................................................................... - 56 -
2.8.2 MAINTENANCE OF DESUPERHEATER...................................................................................................... - 56 -
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Date: 2008-10-20 No.:QN1-SEC-G-04-TP-009 - 2 -
Rev. : A

2.9 BOILER WATER CIRCULATING PUMP........................................................................................................ - 57 -
2.9.1 TECHNICAL SPECIFICATION OF BOILER WATER CIRCULATING PUMP ....................................................... - 57 -
2.9.2 STRUCTURE OF BOILER WATER CIRCULATING PUMP............................................................................... - 58 -
2.9.3 MAINTENANCE OF BOILER WATER CIRCULATING PUMP.......................................................................... - 58 -
2.10 HYDRAULIC PRESSURE TEST OF BOILER................................................................................................ - 62 -
2.10.1 CLASSIFICATION OF HYDRAULIC PRESSURE TESTS............................................................................... - 62 -
2.10.2 QUALIFIED CRITERIA OF HYDRAULIC PRESSURE TEST ......................................................................... - 62 -
2.10.3 CONDITIONS OF HYDRAULIC PRESSURE TEST ...................................................................................... - 62 -
2.10.4 HYDRAULIC PRESSURE TEST ............................................................................................................... - 63 -
2.11 MAINTENANCE OF BOILER STEEL FRAME, PLATFORM HANDRAIL AND MANHOLE................................. - 65 -
2.11.1 STRUCTURE OF BOILER STEEL FRAME.................................................................................................. - 65 -
2.11.2 MAINTENANCE OF BOILER STEEL FRAME, PLATFORM HANDRAIL AND MANHOLE.............................. - 65 -
2.12 SPECIAL TOOLS AND SPARE PARTS AND MATERIAL FOR MAINTENANCE OF BOILER PROPER ................. - 67 -
3 VALVE, WATER LEVEL GAUGE, PI PE AND ACCESSORI ES...........................................................- 68 -
3.1 MAINTENANCE OF SAFETY VALVE ........................................................................................................... - 68 -
3.1.1 STRUCTURE OF SAFETY VALVE ............................................................................................................. - 68 -
3.1.2 MAINTENANCE OF SAFETY VALVE ......................................................................................................... - 69 -
3.2 MAINTENANCE OF SOLENOID RELIEF VALVE ........................................................................................... - 80 -
3.2.1 MAINTENANCE OF SOLENOID RELIEF VALVE ........................................................................................ - 80 -
3.3 MAINTENANCE OF WATER LEVEL GAUGE.................................................................................................. - 85 -
3.4 MAINTENANCE OF DESUPERHEATING CONTROL VALVE........................................................................... - 90 -
3.5 VALVES.................................................................................................................................................... - 92 -
3.5.1 MAINTENANCE OF HP GATE VALVE ...................................................................................................... - 92 -
3.5.2 MAINTENANCE OF HP STOP VALVE....................................................................................................... - 95 -
3.6 BLOWDOWN FLASH TANK........................................................................................................................ - 96 -
3.6.1 TECHNICAL SPECIFICATIONS OF BLOWDOWN FLASH TANK................................................................... - 96 -
3.6.2 MAINTENANCE OF BLOWDOWN FLASH TANK ....................................................................................... - 97 -
4 COAL PULVERI ZI NG SYSTEM ............................................................................................................- 100 -
4.1 STEEL BALL COAL MILL ........................................................................................................................ - 100 -
4.1.1 STEEL BALL COAL MILL TECHNICAL SPECIFICATIONS........................................................................ - 100 -
4.1.2 MAIN TECHNICAL PERFORMANCE....................................................................................................... - 101 -
4.1.3 STEEL BALL COAL MILL MAINTENANCE............................................................................................... - 104 -
4.2 COAL FEEDER........................................................................................................................................ - 124 -
4.2.1 COAL FEEDER TECHNICAL SPECIFICATIONS........................................................................................ - 124 -
4.2.2 COAL FEEDER MAINTENANCE ............................................................................................................ - 125 -
4.3 MAINTENANCE OF THE AUXILIARY EQUIPMENT OF THE COAL PULVERIZING SYSTEM ........................... - 128 -
4.3.1 MAINTENANCE OF THE RAW COAL BIN AND PULVERIZED COAL BUNKER .......................................... - 128 -
4.3.2 COARSE /FINE PULVERIZED-COAL SEPARATOR..................................................................................... - 132 -
4.3.3 MAINTENANCE OF WOODBLOCK SEPARATOR....................................................................................... - 135 -
4.3.4 MAINTENANCE OF WOOD SCRAPS SEPARATOR..................................................................................... - 136 -
4.3.5 AIR LOCKER MAINTENANCE................................................................................................................ - 138 -
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4.3.6 COAL GATE MAINTENANCE ................................................................................................................. - 139 -
4.3.7 EXPLOSION DOOR MAINTENANCE ....................................................................................................... - 139 -
4.4 MAINTENANCE OF PULVERIZED FUEL FEEDER....................................................................................... - 140 -
4.4.1 TECHNICAL SPECIFICATIONS OF PULVERIZED FUEL FEEDER................................................................. - 140 -
4.4.2 MAINTENANCE OF IMPELLER PULVERIZED FUEL FEEDER..................................................................... - 142 -
4.5 PULVERIZED COAL CONVEYER MAINTENANCE...................................................................................... - 148 -
4.5.1 PULVERIZED COAL CONVEYER TECHNICAL SPECIFICATIONS................................................................ - 148 -
4.5.3 PULVERIZED COAL CONVEYER TROUBLE SHOOTING............................................................................ - 154 -
4.5.4 OPERATION AND REPAIR...................................................................................................................... - 156 -
4.6 J ET LUBRICATION UNIT MAINTENANCE................................................................................................. - 158 -
4.6.1 J ET LUBRICATION UNIT TECHNICAL SPECIFICATIONS.......................................................................... - 158 -
4.6.2 J ET LUBRICATION UNIT MAINTENANCE.............................................................................................. - 159 -
4.7 MAINTENANCE OF PRIMARY AIR PIPE ..................................................................................................... - 160 -
4.8 MAINTENANCE OF BAG-TYPE DUST COLLECTOR................................................................................... - 161 -
5 PRI MARY AI R FAN (MI LL FAN), FORCE DRAFT FAN , I NDUCED DRAFT FAN.......................- 162 -
5.1 PRIMARY AIR FAN (MILL FAN)................................................................................................................. - 162 -
5.1.1 TECHNICAL SPECIFICATIONS OF PRIMARY AIR FAN............................................................................... - 162 -
5.1.2 MAINTENANCE OF PRIMARY AIR FAN................................................................................................... - 163 -
5.2 FORCE DRAFT FAN.................................................................................................................................. - 170 -
5.2.1 TECHNICAL SPECIFICATIONS FORCE DRAFT FAN .................................................................................. - 170 -
5.2.2 TECHNICAL SPECIFICATIONS OF FORCE DRAFT FAN OIL STATION.......................................................... - 173 -
5.2.3 MAINTENANCE OF FORCE DRAFT FAN AND HYDRAULIC FLUID STATION............................................... - 173 -
5.3 INDUCED DRAFT FAN MAINTENANCE.................................................................................................... - 183 -
5.3.1 TECHNICAL SPECIFICATIONS OF INDUCED DRAFT FAN......................................................................... - 183 -
5.3.2 FUNCTION DESCRIPTION...................................................................................................................... - 187 -
5.3.3 PARTS DESCRIPTION............................................................................................................................ - 190 -
5.3.4 INDUCED DRAFT FAN MAINTENANCE................................................................................................. - 192 -
5.4 MAINTENANCE OF FUME DUCT AND AIR DUCT....................................................................................... - 199 -
5.5 AIR HEATERS AND PIPE MAINTENANCE ................................................................................................. - 202 -
6 ESP..............................................................................................................................................................- 203 -
6.1 ESP TECHNICAL SPECIFICATIONS........................................................................................................... - 203 -
6.2 STRUCTURE OF ESP............................................................................................................................... - 203 -
6.3 MAINTENANCE OF ESP.......................................................................................................................... - 203 -
6.3.1 MAINTENANCE OF CATHODE WIRE AND ANODE PLATE ...................................................................... - 205 -
6.3.2 CATHODE, ANODE RAPPING UNIT MAINTENANCE................................................................................. - 210 -
6.3.3 MAINTENANCE OF CATHODE SUSPENSION DEVICE AND LARGE/SMALL FRAME .................................... - 214 -
6.3.4 MAINTENANCE OF OTHER AUXILIARIES OF ESP.................................................................................. - 215 -
6.3.5 ESP ASH HOPPER AND SLIDE DAMPER.................................................................................................. - 218 -
6.4 TESTS AFTER ESP MAINTENANCE .......................................................................................................... - 219 -
6.4.1 PREREQUISITE FOR ACCEPTANCE TEST ................................................................................................ - 219 -
7. DOUBLE SCREW ROD AI R COMPRESSOR(ZRSERI ES)...............................................................- 221 -
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7. 1 DOUBLE SCREW ROD AIR COMPRESSOR TECHNICAL SPECIFICATIONS..................................................... - 221 -
7. 2 DOUBLE SCREW AIR COMPRESSOR STRUCTURE ..................................................................................... - 221 -
7. 3 MAINTENANCE LEVEL FOR DOUBLE SCREW AIR COMPRESSOR.............................................................. - 225 -
7.4.1 MAINTENANCE PREPARATION:............................................................................................................. - 226 -
7.4. 2 DISMANTLING OF UNIT SYSTEM PARTS: .............................................................................................. - 226 -
7.4.3 DISMANTLING OF MINIMUM PRESSURE VALVE, OIL CUTOFF VALVE, AIR INLET VALVE AND OIL PRESSURE
REGULATOR ................................................................................................................................................. - 227 -
7.4.4 CHECK, VERIFY, REPAIR, REPLACE SYSTEM PARTS............................................................................... - 227 -
7.4.5 WASHAFTERCOOLER:........................................................................................................................... - 228 -
7.4.6 CHECK SENSORS ................................................................................................................................. - 228 -
7.4.7 RECOVER............................................................................................................................................ - 228 -
7.4.8 STARTUP COMMISSIONING:.................................................................................................................. - 228 -
8 OI L FREE SCREW AI R COMPRESSOR ..............................................................................................- 229 -
8.1 TECHNICAL SPECIFICATIONS.................................................................................................................. - 229 -
8.2 OIL FREE SCREW AIR COMPRESSOR CONFIGURATION............................................................................ - 229 -
8.3 MAINTENANCE AND SERVICE................................................................................................................. - 229 -
8.4 COMMISSIONING.................................................................................................................................... - 230 -
9 REFRIGERATED AI R DRYER...............................................................................................................- 231 -
9.1 RSL TYPE REFRIGERATED AIR DRYER TECHNICAL SPECIFICATIONS...................................................... - 231 -
9.1.1 WORKING PRINCIPLE DESCRIPTION.................................................................................................... - 231 -
9.1.2 REFER TO FIGURE 1 FOR THE WORK PROCEDURE OF THE REFRIGERATED AIR DRYER. .......................... - 231 -
9.1.3 PROCESS DESCRIPTION....................................................................................................................... - 232 -
9.2 MAINTENANCE AND SERVICE................................................................................................................. - 233 -
9.2.1 PRINCIPLES......................................................................................................................................... - 233 -
9.2.2 CONTENT ............................................................................................................................................ - 233 -
9.2.3 RSL AIR DRYER TROUBLESHOOTING............................................................................................... - 234 -
10 GASI FICATI ON BLOWER ...................................................................................................................- 238 -
10.1 TECHNICAL SPECIFICATIONS................................................................................................................ - 238 -
10.1.1 WORKING PRINCIPLE........................................................................................................................ - 238 -
10.2 MAINTENANCE AND SERVICE OF THE BLOWER CAN BE AS PER THE TABLE BELOW. ............................... - 241 -
10.2.2 ASSEMBLING..................................................................................................................................... - 243 -
10.3 MAIN PARTS AND CONSUMABLES........................................................................................................ - 248 -
10.3.1 LIST OF MAIN PARTS......................................................................................................................... - 248 -
10.3.2 CONSUMABLES................................................................................................................................. - 249 -
11 SLAG REMOVAL SYSTEM...................................................................................................................- 250 -
11.1 SLAG HOPPER MAINTENANCE AND SERVICE........................................................................................ - 250 -
11.1.1 SLAG HOPPER AND SLAG GATE STRUCTURE .................................................................................... - 250 -
11.1.2 SLAG HOPPER AND MAINTENANCE AND SERVICE ............................................................................. - 250 -
11.2 SLAG CRUSHER MAINTENANCE AND SERVICE ..................................................................................... - 254 -
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Rev. : A

11.3 SLURRY PUMP MAINTENANCE AND SERVICE........................................................................................ - 258 -
11.3.1 TECHNICAL SPECIFICATIONS............................................................................................................. - 258 -
11.3.2 SLURRY PUMP MAINTENANCE.......................................................................................................... - 259 -
11.4 DEHYDRATION GRANARY MAINTENANCE AND SERVICE...................................................................... - 263 -
11.4.1 BRIEF INTRODUCTION ....................................................................................................................... - 263 -
11.4.2 PROCEDURE AND QUALITY STANDARDS ........................................................................................... - 263 -
11.5 MAINTENANCE OF CONCENTRATION TANK AND BUFFER TANK............................................................ - 265 -
11.5.1 MAINTENANCE PERIOD: AS PER THE SYSTEM OVERHAUL.................................................................. - 265 -
11.5.2 MAINTENANCE ITEMS....................................................................................................................... - 265 -
11.5.3 MAINTENANCE PROCEDURE AND QUALITY STANDARDS.................................................................... - 265 -
11.6 MAINTENANCE OF PUMPS IN THE SLURRY SYSTEM.............................................................................. - 266 -
11.6.1 HIGH, MEDIUM, AND LOW PRESSURE PUMPS..................................................................................... - 266 -
11.6.2 BACKWASHING PUMP........................................................................................................................ - 270 -
11.6.3 DREDGE PUMP .................................................................................................................................. - 270 -
11.6.4 LIFT PUMP......................................................................................................................................... - 270 -
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1 Main Technical Specifications and Structure of Boiler ( Taking
SG-995/17.3-MMX Boiler as Example)
1.1 General
W-flame boiler has a different structure from regular coal-fired boiler. Its combustion
chamber consists of lower combustion chamber and upper burn-out chamber. The depth of
combustion chamber is 80%-120% greater than that of burn-out chamber. The top of the front
project part form the arch, on which the pulverized coal flow and secondary air nozzles are
placed (Some W-flame boiler arches are only equipped with pulverized coal flow and steam
exhaust nozzles). The jeting down pulverized coal extends downward after being fired. In the
lower part of combustion chamber, it meets tertiary air, then turns upward, rising along the axis
of furnace chamber, thus forming the W-shape flame. The burned product rises to the burn-out
chamber.
Generally, the W-flame boiler is divided into wet bottom boiler and dry bottom boiler. The
aboard practice indicates the biggest problem from W-flame wet bottom boiler is the large
amount of NOx emission, further, there are also problems such as high temperature erosion of
water wall tube, long time of maintenance, weak capability of peak load regualtion. So in
general, the wet bottom boiler is not adopted; W-flame dry bottom boiler can steadily burn
anthracite and meager coal, Vdaf=6%~20%, and even the anthracite, Vdaf=4% can also be
burned. So, this kind of boiler is recommended by general aboard companies. The boilers
having been put into services are also such kind of boilers.
To ensure the burning of anthracite or meager coal, the primary air rate of W-flame boiler is
lower, which is 15% to 20%. For the penetrating depth is insufficient due to the own air amount
and flow rate of primary air,large amount secondary air must be send from the arch. The lead jet
of secondary air from the arch is utilized to ensure the better penetration depth of the primary
air.
1.2 Technical Specification of the Boiler
Supplier: Shanghai Electric Group
Type: SG-995/17.3-MXX
Style: Subcritical controlled circular drum furnace, double arch W-flame single
furnace, axial burning, primary middle reheated, two-stage attemperating, balancing
ventilating, openair disposed, dry ash handling, all-steel structural, all suspended
structural II-model boiler

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Boiler Type SG-995/17.3-MXX
Main parameters of boiler
B-MCR t/h 995
Rated evaporation(RO) t/h 889.1
Steam Pressure (B-MCR/RO) MPag 17.29/17.13
s
u
p
e
r
h
e
a
t
e
d

s
t
e
a
m

Steam Temperature(B-MCR/RO) 541/541
Steam flow(B-MCR/RO) t/h 882.498/736.407
Inlet,outlet steam pressure(B-MCR) MPag 3.53/3.34
Inlet,outlet steam pressure(RO) MPag 3.14/2.98
Inlet,outlet steam temperature(B-MCR) 320/540
R
e
h
e
a
t
e
d

S
t
e
a
m

r
e

Inlet,outlet steam temperature(RO) 309/540
Feedwater temperature(B-MCR/RO) 281/273
1.3 Boiler Structure
The boiler proper is designed by Alstom, and its technical support of commisioning and
performance test is also supplied by Alstom, it is made by Shanghai Boiler Works, Ltd. The
style of boiler is double-arch W-flame single-furnace, primary middle reheated, forced water
circular, subcritical drum boiler. Two units are equipped with one startup boiler, which acts as
the startup steam source during the unit startup;
The coal type of the boiler is anthracite, which is from CAM PHA mineral area and HON
GAI mineral area in Vietnam.
Combustion system: it adopting hot air for pulverized coal feeding, each boiler equipped with 16
dual-split double direction pulverized coal feeders and 32 burners. The capacity of pulverized
coal burner is 100% BMCR of designed coal type. The startup and flame stablizing of boiler
uses heavy oil, according to standard of TCVN 6239-2002. The boiler employs two-stage
ignition, i.e., the heavy oil gun is fired by the electric spark of high-energy ignitor, then the heavy
oil gun ignite the pulverized coal. Oil gun adopts steam atomization. For the project, 25000 ton
oil tanks, 2 oil drain pump, 2 100% capacity AC/DC oil feeding pump, 1 dirty oil pump and 1
sewage pump are disposed.The fuel system is disposed the oil feed pipe/oil return pipe to
burner of boiler according to the principle of single oil feed/return main pipe.
Oil burner: there are 8 heavy fuel oil HFO) burner at each folded flame corner, i.e., each boiler
equipped with 16 burners. Auxiliary steam with pressure stablized at 5.25 bar(g) allow HFO
attain at atomization state, the auxiliar steam is also used for burner clean. The heavy oil is
ignited via the high energy ignitor, each HFO burner is equipped with special flame inspector.
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Cooling wind is provided to burner and flame inspector via two independent special loops.
During stop, fuel burner retreated from burner nozzle about 330 mm, to prevent the affection of
boiler radiation( avoiding the burnout of oil burner). All burning capacity (LHV base value) 30%
BMCR fuel heat input value, only adopting 12 burners can attain 30% BMCR burning capacity
(two burners per folded flame corner stop operation). The regulation ration of burner is 1:5. J11
oil burner is employed.
Smoke exhaust and ash system of boiler: the smoke exhaust system adopts negative
balancing ventilation style, smoke and gas come from ESP to FGD, then exhausted to
atmosphere, or directly vented to atmosphere via FGD bypass. Induced/forced draft fan is axial
type, forced draft fan is adjustable moving-blade one, and induced fan is adjustable static-blade
one. The pulverizing system is warehouse type, smoke drying pulverizing system, adopting
negative pressure ventilation. Each boiler is equipped with two single-in-single-out BBI ball
miller. The primary fan (pulverized coal exhauster) use centrifugal fan. The smoke exhaust
goes through the fabric filter undergoing the pulverized coal filtering, and then to the smoke
exhauster, being vented to the atmosphere.
Ash handling and ash yard: dry bottom handling style is adopted. The bottom ash
is discharged to ash sump via the slag crusher, hydraulic ejector. The ash collected
from air preheater, ECO and electric precipitator is sent to large scale ash silo (each of
the two silos has capacity of 2500 m3). Dry ash is further sent to ash slurry pond
through blending of ash and water, and then conveyed to ash yard by ash slurry pump
(Composite utilization of dry ash is kept at the same time).
Dust collection and desulphurization system: four-electric field electrostatic precipitator is
chosen. For this phase, a 200m-height dual steel flue stack will be built. Synchronously, 100%
capacity FGD is to be built, adopting wet desulphurization process, limestone-plaster forced
oxidation, using gas - gas heat exchanger (GGH);
Compressed air system: this system is considered according to less lubricant, three 50%
capacity compressors are equipped.
Safety valve: Spring loaded safety valves from Crosby Company of U.S.A. are used for the
boiler. Detailed position: 3 pieces for boiler furnace 1 piece disposed at outlet pipe of
superheater, 2 pieces for inlet pipe of reheater, 2 pieces for outlet pipe of reheater, also a
electromagnetic relief valve(ERV) is placed at outlet pipe of superheater, with brand of VTI,
USA, supplied in whole unit by Crosby Company. The maximum evaporation is 995t/h, total
discharge amount of safety valve of boiler drum is 881.796t/h, accounting for 88.62% of
maximum evaporation, the discharge amount of superheater safety valve is 153.86t/h, account
for 15.46% of maximum evaporation, the sum of total discharge amount of boiler drum and
superheater is 1035.656t/h, being 104.09% of maximum evaporation. The maximum flow rate
of reheated steam is 848.6t/h, the sum of total discharge of reheater inlet safety valve is
512.94t/h, accounting for 60.45% of maximum flow rate of reheated steam, the sum of total
discharge of reheater outlet safety valve is 379.157t/h, accounting for 44.68% of maximum flow
rate of reheated steamthe sum of total discharge of reheater inlet/outlet safety valve is
892.097t/h, account for 105.13% of maximum flow rate of reheated steam. The discharge rate
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of dynamic discharge valve is 166t/h, occupying 16.68% of total evaporation of boiler, its
discharge will not be included in discharge rate of safety valve.
2 Boiler Proper
2.1 Drum
2.1.1 Specification of drum
In the drum, along the direction of length, arranged circular interlayer, eddy-current
separator, corrugated plate separator, louver moisture separator, water feeding distribution
header, continuous blowdown pipe and inlet flow equalizing plate, cross plate of downcomer.
2.1.2 Equipment inside the drum
Designation Quantit
y
Material Designation Quantit
y
Material
Arc diaphragm 14 pcs AY3F Inlet equalizing pipe of
downcomer
4
Seat plate of separator 14 pcs AY3F Cross plate of
downcomer
4

Lower support of
separator
56 pcs EG25 Pipe 485, L406
4
20 steel
Eddy-current separator
56 pcs
Sampler inside the drum
1

Corrugated plate dry
box
72
Pipe 514, L566
36
20 steel
Sluice tube plate
18
Pipe 514, L
18
20 steel
Water feeding
distribution header
1
Pipe 514, L
18
20 steel
Blowdown piping
1
Stud connection
12

Sluice pipe
18

2.1.3 Drum maintenance inspection
Maintenance
item
Workmanship and precautions Quality standard
I Maintenance
preparation
1. Remove insulation cover of manhole at both
sides, remove the manhole door screws with
drum manhole special gate spanner. After
remove, the manhole screws and nuts should
be placed in special oil tank or oil disc to

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avoid loss and rust.
2.Open manhole door, mount draft fan to cool
down the inside of drum. Maintenance
person can only enter the drum after the
temperature of drum decrease below 40.
3. To prevent the tools and parts fall into the
downcomer, after take down the filter screen
of downcomer, rubber should be laid on the
bottom of drum. When carry out job inside the
drum, the maintenance person must strictly
comply with the requirement of Clause 270 of
Safe Operation Regulation of Electric
Industry(Thermal Machinery Section).
4.electric tools and lighting used in drum must
meet the requirements of Clause 272, 273
and 274 of Safe Operation Regulation of
Electric Industry(Thermal Machinery
Section) issued by certain Ministry.
5. After the open of manhole door, temporary
manhole gate must be mounted. During the
maintenance, the maintenance person should
close the temporary manhole door when he/she
leave the drum.
II Inspection of
facilities &
accessories
inside the drum
and dirty clean
1. Firstly, the chemical supervision personnel
inspects the fouling and rust inside drum and
the surfaces of inner facilities.
2. Check and record the completeness,
leakproofness and security.
3. Check the connection screw and fastening
screw of moisture separator.
4. Clean the surface fouling of drum and
moisture separator.
Caution: Do not damage the glossy
anticorrosion film on the metal or its surface.
5. Clear and dredge the blowdown pipe, sample
pipe, chemical feed pipe, connection pipe of
water gauge and pressure meter.
1. The completeness of
the moisture separator,
without loose, tilting
and corrosion; the
louver has no damage
and deformation .
2. No fall-out, loosing to
the connection screw
and fastening screw of
moisture separator.
3. Cleanness of the inner
surface of drum and
surfaces of moisture
separator and
accessories.
4. Free-flowing in the
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blowdown pipe, sample
pipe, chemical feed pipe
and connection pipe of
water gauge and
pressure meter.
III remove &
assembly of
facilities in drum
1. Before disassembly, number the moisture
separator according to sequence of
left-right-front-back.
2. When dismantling, first remove the draining
pipe and the cyclone separator barrel and
connection screw and fasten screw of top
hat, then take down the separator and top
hat.
3. Remove the connection screw of support
plate of dry box; draw out the dry box along
the support plate.
4. After remove the connection screws and
fixed screws, count out them, and not to leave
them in the drum.
1. Moisture separator
and cleaning hole
mounted correctly.
2. Cyclone separator
cartridge and top hat
may be kept vertical and
smooth.
3. No loosing of the
connection screw and
fixing screw.
IV Inspection of
welding joint
inside/outside
the drum, inner
wall corrosion
and crack
1. Polish the surface of longitude joint and
circular joint of inside/outside the drum and
100-150mm area along weld with polisher.
Detailed section and length should be
stated by the metal supervision personnel.
2. After clean of drum inner wall, check
erosive point and crack on the surface of
inner wall. If common erosive points and
cracks are found, polish them with
polisher. For serious erosive points and
cracks, report to higher technical
department for making special technology
measures.
1. Polish the weld and
surfaces along the
weld, removing the
fouling and rust,
showing the original
metal color.
2. After erosive point
and crack polishing,
such polished section
should be flat and
smooth, having no
edges and corners.
V downcomer
pipe and other
visible pipe seat
weld inspection

1. According to requirements of metal
supervision, polish the edges of drum
downcomer seat weld. After that, the metal
supervision personnel carry out flaw
detection on polished surfaces.
2. Clear the fillet weld of cross plate of
1. Edges of downcomer
seat inside the drum
have no crack.
2. the fillet welds of
cross plate of
downcomer have no
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downcomer, and inspect the fillet welds. If
cracks exist, polish them until removal.
3. Inspection of fillet welds of connection
pipe seats of blowdown, chemical feed,
water gauge and pressure meter. If cracks
exist, deal with them.
4.Grind the edges of pipe seat corners of
safety valve with polisher, and give flaw
inspection to fillet welds by the metal
supervision personnel.
crack and erosion.
3. The fillet welds of
connection pipe of
blowdown, chemical
feed, water gauge
and pressure meter
have no cracks.
safety valve pipe seat
have no crack.
VI Weld
inspection of
inner parts of
drum

1. Check the circular isolating plate and
upper side plate welds with light
transmission method, if any, repair weld.
2. Check the tee pipe of water distribution
pipe and side heads with light transmission
method. If any cracks, repair weld.
3.Clear embedded parts welds of manhole
hinges. If any cracks, grind and repair weld
them.
Note: Do not generate arc from drum.
1. The welds of circular
isolating plate and
side plates have no
cracks.
2. Welds of Tee of
water distribution
pipe and side heads
have no cracks.
manhole hinges have
no cracks.

VII Drum
levelness
measurement
1. The drum levelness measurement shall
base on the horizontal central lines of side
circumference.
2. Use a rubber pipe with glass pipe plugged
in both ends, full water in the rubber pipe,
and put the two end glass pipe on the side
circumferential horizontal lines.
3. Measure and record the distance from
drum central line to glass pipe water level,
compare the distances of two sides. The
difference is deviation of drum levelness.

VIII Maintenance
of manhole door
1. Clear the junction surface of doorframe
and doorplate of the manhole door with
1 The junction surface
of frame and plate
should be smooth.
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butt chisel and sand paper.
2. Check the junction surface of doorframe
and doorplate. If cracks or flaw points
exist, grind them. For trace of blowing
damage, carry out bead welding after
grind, and then grind it again.
3. Kerosene should be used for clean of the
screws and nuts of the manhole door; and
then check the threads of such screws and
nuts. The thread burr should be repaired
with file or on the machine tool; for those
have serious fault, change them.
4.The hardness of screw should be checked
for each over haul.
Use special flat ruler
and filler gauge to
check 12-1 points
along circumference
of the grinded
surface, the error
should be less than
0.1-0.2mm.
2. The screws and nuts
of manhole door have
no burrs and breaks.
3. Screw hardness HB
197.
IX
support/suspen
sion frame
check
1. Check the contact of derrick and drum.
2. Check the appearance of suspension nut
of derrick.
3. Check the appearance of derrick.
1. Derrick and drum
well contacted,
having large contact
area.
2. The suspension nuts
of derrick are even
loaded, and have no
erosion on surface.
3. The derrick surface
has no erosion.
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X close of
manhole

1. After the maintenance inside drum, the
maintenance tools should be taken out, and
count, reviews them.
2. Last inspection should be given to drum
before close manhole.
3. Before close manhole, the high pressure
seal gasket, and coat the door frame, door
plate, screws and nuts with molybdenum
disulfide.
4. After close the manhole, check the contact
circumstance of junction surface with filler
gauge.
5. After cold state fasten of the manhole door,
hot fasten the door again when the
pressure increase to 0.3O.5MPa.

1. No foreign matter in
the drum.
2. The junction surface
is well contacted after
manhole closed.
3. The fixing screws are
even loaded after
manhole closed.

2.2 Lower Drum
2.2.1 Lower drum technical specification
The circular structured lower drum, 914mm, will replace lower header of all evaporation
heating absorption area. It has the same function with normal low header of boiler water wall.
The lower drum is equipped with multi-hole strainer cover and orifice plate, the diameter of
strainer is 0.6mm with opening area ratio of 52%. The function of the strainer is to prevent the
foreign matter entering the water wall tube. The orifice plate is mounted in the inlet end of the
water wall tube. Each tube is equipped with orifice plate. The function of the orifice plate is to
normally distribute the feed water, ensuring the safe operation of water wall. The diameter of
orifice plate is calculated for each loop and each water wall tube according to heat load
distribution curve along the direction of furnace height and the different flow resistance under
different working condition.
2.2.2 Maintenance of lower drum
Maintenance item Workmanship and precautions Quality Standard
I Preparation before
maintenance
1. After the open of manhole, the
chemical supervision personnel enter
the drum to check the erosive points
and sample the scale.
2. Pave rubber on the nozzle of front and
rear drain pipe to prevent the falling in

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of tools.
II Disassembly of
orifice plate

1. Number the cover of multi-hole
strainer, remove the fixed screw of the
cover, and take down it.
Note: After remove the screws of cover,
take them out of the drum, and count
them.
2. Group and number the orifice plate.
3. Remove the retainer enclosed the
orifice plate, take down the orifice
plate.
Note: After remove the screws of cover,
take them out of the drum, and count them
to store collectively.
4. After removal, the orifice plate must be
put into oil disc or other container to
wash. If meet with acid cleaning, the
orifice plates and multi-hole strainer
cover may not be removed, cleaning
with the system. But, after that, spot
check a group of orifice plate to find
the result of acid cleaning.
5. After plate clean, spot check orifice
plate to measure the diameter of hole.
If the diameter exceeds the standard,
change the plate.
6. Assemble the orifice plate according
to the number. Do the same with
strainer cover.
7. After reassembly of orifice plate
retainer, check the looseness.
1. The orifice plate is
smooth, with correct
mounting position.
2. After assembly, the
orifice plate should be
secure without loose.
3. The surface of
strainer cover should
be smooth and clean.
4. The mounting
position of multi-hole
strainer cover is
correct. And the
cover has no loose
after installation. 5.
The change rate of
hole diameter of
orifice plate should be
less than 5%.

III Inside clean of
lower drum

1.Clear the fouling in the inner wall of
lower drum, pipe seat of water wall
and of downcomer with wire brush and
compressed air.
2. Clear the fouling on the surface of
1.The inner wall of
lower drum is
smooth, free of
fouling.
2.There is no fouling on
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mulit-hole strainer cover with wire
brush and compressed air.
the pipe seat of water
wall and downcomer.
3.The orifice plate is flat
and smooth.
4.The surface of
strainer cover is
smooth, free of
fouling.
2.3 Water Wall
2.3.1 Technical specification of water wall, steam-water connection pipe, water wall header.
The water wall, adopting all welding type membrane water wall, together with drum,
furnace water circling pump and lower drum etc., form several force-flow independent loop. The
water wall has two types, i.e., smooth pipe and inner thread pipe.
2.3.2 Maintenance of water wall and header
Maintenance
item
Workmanship and precautions Quality Standard
I Preparation
of water wall
maintenance

1.Erect firm and stable scaldfold from bottom ash
hopper to inlet elbow of wall reheater around ther
furnace.
2.When use elevating platform in furnace, make
sure to operate according to sepecification.
Note: Do not exceed the limited weight or serve as
lifting tool when use elevating platform.
3.Certain number of lights should be put in the
furnace to ensure sufficient lighting of the
furnace. The power line to the furnace should be
overheaded.

II Coke and
ash cleaning
of water wall

1.Before coke cleaning of water wall, a wood board
should be paved on the slope of bottom ash
hopper to separate the furnace and the hopper, in
order to prevent strike of coke on the slope water
wall tube.
2.Strike the coke suspending on the water wall
upside down with hammer, let it break away from
the water wall.
1.There is no coking
or ash deposit on
the surface of
water wall.
2. No damage to the
water wall surface.

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Note: Do not damage the water wall when stike and
remove the coke.
3. Remove the thin coke and ash deposit attached
to the water wall with round spade along the
surface of water wall.

III Visual
inspection of
water wall

1.Use thickness tester to measure the water wall
thickness besides the burner and around the blow
hole of soot blower and the thickness of
suspending pipe.
2. Use a slide caliper or caliper gauge to measure
the expanded value of pipes along the both sides
of burner and suspended pipe at furnace outlet.
Note: Remove the ash deposit on the surface of
pipe with brush before measurement.
3. Check the deformation, pits of water wall tube of
bottom ash hopper slope and erosion points near
the water seal trough.
4. Check the crack of fin of water wall, if any, repair
weld with electric welding.
5.With respect to water wall tube at high heat
loaded area, also performance the high
temperature erosive inspection.
1. The reduced value
of thickness of
worn pipe should
be less than 30%
of tube thickness.
2. The expanded
value of pipe
should be less
than 3.5% of tube
diameter.
3. The slope water
wall of bottom ash
hopper has no
deformation and
pits, the depth of
erosive points of
tube should be
less than 30% of
tube thickness.
4. The fins of water
wall have no
crack.
IV Sampling
of
supervision
tube

1.The location of supervision tube of water wall may
be determined by the metal supervision
personnel.
2. For the cut of supervision tube, the cutting point
should avoid the rigid beam of water wall, and
also stagger with the weld of adjacent tube, the
distance staggerred may be more than 50 mm.
Further, after cut, the fin of water wall should be
cut more than 25mm along the wall to ensure the
welding quality.
3. The length of supervision tube usually is not less
1. The cut position of
tube is correct.
The distance that
cut point away
from the rigid
beam and bend
start point of elbow
should be more
than 150 mm. The
cut point shoud be
more than 150 mm
away from the
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than 250 mm, the sampling tube should include
the new and old section.
4.During the cutting, do not damage the tube proper
and adjacent tube. Try to use machine to perform
the cut and avoid the falling of weld slag into the
tuge when using flame cutting. Following
completion, seal the tube open to the top.
5. After remove the supervision tube, show the
location of supervision tube, the side facing flame
and flow direction of fluid in the tube.
adjacent weld
seam at same
tube.
2.The sample tube
and adjacent tube
have no damage.
V
Replacement
of tube
1.Following the tube cut, use facing machine to
make the divided edge of cross section. Before
butt welding, the pipe inner/outer wall should be
ground until showing proper metal color. The
length to be ground is 10-15mm in general.
2.Before the cut of new tube, visual inspection and
pipe thickness measurement should be given to
tube. For curved tube, the ellipticity of bending
section should be carry out and given ball passing
test. Additionally, aid cleaning may be
implemented before use, and purge the tube by
the aid of compressed air before butt welding.
3.Argon arc weld may be used for pipe, or with the
argon arc weld as the backing, electric weld as
the covering technology. There will leave 3 mm
gap between pipes.
Note: Do not butt weld forcely. After the tack weld,
not to strike with hammer.
4. Following the of weld, carry out flaw detection to
the tube. The fins can be restored after confirm
the qualification of weld seam. The expansion
efficient of fins should be in line with that of fin
tube. Seal welding will be adopted.
5.When replacing suspended tube, the cold-drawn
dimension of tube should be measured and
recorded after the cutting of tube to ensure the
cold-drawn value during the restore of tube.
When replacing several suspended tubes, it

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should be done one by one. Do not cut two or
more tubes at the same time.
2.4 Superheater, Reheater and Header
2.4.1 Specification and structure of superheater and reheater
2.4.1.1 Structure of superheater and reheater
According to gas flow process, the superheater system is divided into five stages,
i.e.,separation platen, rear platen, last stage, enclosure and low temperature superheater;
according to steam flow process, such system is divided into such five stages as top furnace,
low temperature superheater, separation platen, rear platen and last stage convection
superheater:
Reheaters are well distributed at high temperature gas area, they are classified into
three stages: wall reheater, platen reheater and last stage reheater. The wall reheater is low
temperature reheater, disposed at front wall on top of furnace and front side of two-side walls,
close to the water wall and cover the water wall.
2.4.1.2 Technical specification of superheater and reheater
The wall thickness of superheater tube is determined by strength, of which the material is
depended on work temperature of superheater and relied on the principle of safety and
economic.
No. Item Unit
1. Saturated steam tube
Nominal outer diameter mm 57/44.5
Longitudinal distance mm 127.5/153
Material
Quantity 136
Outlet steam temperature 362
Pressure drop from lower drum to superheater outlet
under condition of BMCR
kg/cm
2
14.1
2. Saturated steam header
Quantity 1
Nominal outer diameter mm 244.5
Nominal bore diameter mm
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Length m About 15.8
Material SA106 C
3. 1
st
stage superheater
Quantity 1
Gap of tranverse gas flow mm 102
Gap of gas flow direction mm 89
Nominal outer diameter of tube mm 44.5
Heat absortion area(effective) m
2
about 8150
Total circumferential heat area m
2
Should be
announced
Gas duct area m
2
Should be
announced
Material SA210C
SA209T1
Platen quantity 149
Steam flow tube number 447
Total effective heat absorption area of
superheater(net weight)
m
2
About 8150
Pressure drop from lower drum to superheater
outlet under condition of BMCR
kg/ cm
2
2.1
Steam flow rate in the desuperheater m/s 6.7
Maximum gas flow rate under condition of BMCR m/s 10.5
4. Inlet header of 2
nd
superheater(platen type)
Quantity 1
Length m About 16.3
Material SA106C
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5. 2
nd
Quantity 1
Transversal gas flow mm 765
Along flow direction mm 58.3
Effective heat absorption area m
2
1610
Material SA213T22
SA213T2
SA213T11
SA213TP347H
Platen quantity 19
Gas flow tube number 266
m
2
1610
kg/ m
2
3.8
6. Inlet header of 2
nd
Quantity 1
Nominal outer diameter mm
Nominal inner diameter mm 260
Length m About 15.6
Material SA335P22
7. Platen superheater N/A
8. Inlet header of superheater
Quantity 1
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Nominal bore diameter mm Should be
announced
Length m About 15.8
Material SA335
P12
9. Last stage superheater
Quantity
Tube gap
Gap of transversal gas flow mm 127.5
Gap of gas flow direction mm 76
Nominal outer diameter of tube mm 38
Effective heat absorption area m2 About 4070.
Material SA213T22
SA213T9.1
m2 About 4070.
kg/cm2 2.1
10. Outlet header of last stage superheater
Quantity 1
Nominal outer diameter mm
Nominal bore diameter mm 280
Length m About 16.4
Material SA335
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P91
11. Desuperheater
Method Water
spraying
Control range of superheater 60%~100%
Control range of reheater 60%~100%
Maximum water spraying amount(superheater/
reheater)
kg/h 20000/25000
12. Inlet heater of low temperature reheater
Quantity 1+2
Nominal bore diameter mm
Material SA106C
13. Low temperature reheater
Quantity 1
Gap of transversal gas flow mm 51
Gap of gas flow direction mm N/A
Heat absorption area(effective) m2 500
Material
Platen quantity 602
Steam flow tube number 602
Departure temperature 389
m2 500
kg/m2 0.7
Control equipment of steam temperature m/s 27.0
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Maximum gas flow rate under condition of BMCR m/s N/A
14. Outlet header of low temperature reheater Should be
announced
Quantity 1+2
Material SA335P12
2.4.2 Maintenance of convection superheater
Maintenance item Workmanship and precautions Quality standard
I Ash cleaning of
heat absorption
surfaces

1.With compressed air, clean upside down
the ash deposits on the low temperature
superheater, tube surfaces of enclosure
superheater and horizontal gas duct.
2. Rinse the ash deposits on the surfaces of
tubes of separation platen superheater,
rear platem superheater and last stage
superheater.
3.When flush with water, protective work for
back stack well should be done to prevent
water entering the back stack well.
4. When blow coke around the enclosure
superheater, coke blocks should be broken
with hammer for further cleaning.
Note: Do not damage the tube.
1.No ash deposit
and coking on
heating surfaces
of tube.
2.There is no
coking and other
foreign matter
between tube
rows.

II Anti-wear
inspection of tube for
heat absortpion

1.Pay more attention to inspect the straight
tube section of low temperature
superheater tube row on both sides of
suspended tube, 90elbow of upper/lower
connection tube, elbow of upper/lower tube
rows close to the back enclosure, and
tubes with the blow range of blower. If worn
tube is found, then measure the thickness
of tube with thickness tester. And
separately spot check two tubes to
measure and record tube thickness.
2.Emphasisly check the contact section of
The reduced
thickness of tube
should be less
than 30% of tube
thickness.

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platen superheater and horizontal position
tube, tube of last stage superheater
deformed tube row, tubes within the range
of blow of blower. If worn tube is found,
then measure the thickness of tube with
thickness tester. Also spot check and
record tube thickness.
3.Check the rear enclosure tube at gas inlet
section of low temperature superheater
and economizer, and enclosure tube
around the blow hole of blower.

III Creep expansion
inspection of tube at
tube heat absorption
area

1.With slide caliper or pipe caliper, measure
the tube diameter of lead tube of low
temperature superheater, outer tubes of
separation platen superheater, outer tubes
of rear platen and the first tube at
flame-facing side of last stage superheater.
Note that before measurement, clean the
ash deposits on the surface of tube and
coke attaching to the surface of tube.
During measuring, the slide caliper should
be perpendicular to tube.
2.Macroscopic inspection of the appearance
of tube.
1.The expansion
value of carbon
steel tube of
superheater is
less than 3.5% of
tube diameter.
2. The expansion
value of alloy
steel tube of
superheater is
less than 2.5% of
tube diameter.
3.The appearance
of tube has no
obvious color
variation.
4.There is no crack
on the surface of
tube, and the
thickness of
oxide skin should
be less than 0.6
mm.
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IV Inspection and
reshaping of tube
row

1.Check the flatness and transversal pitch of
tube row. If deflection or curving exist to
tube row, find the reason of distortion or
the deformation points. According to the
reason, change the tube clip, restore the
flatness of tube row. For serious deformed
tube rows or single deformed tube deviate
from tube row, the deformed section
should be cut away to restore the origin
pitch and flatness, and then recover by the
aid of new tube. Change the transversal
live connection board of deformed tube
row, retighten the connection of platen
superheater and horizontal location arm to
restore the transversal pitch of tube row.
2. When replacing the tube clip or strap,
electric weld or grinder may be used to cut
the original parts. Note, do not damage the
tube when carry out cutting. Before welding
of fixing block of tube clip and strap, grind
the crator left on the tube.
3.When replacing the tube clip, be sure not to
weld the clip and tube together, similarly,
the tube straps can not be weld each other
when to be replaced.
4.The material of fixing parts should be the
same to that of original parts.
1.The tube rows
are flat, and
transversal
pitches are even.
2.The tube clip,
tube strap and
transversal live
connection board
of tube row are
sound, without
shedding,
burning out,
deformation, they
are well fixed to
tube row and can
freely expand
with tube.
3.Horizontal
locating tube and
platen
superheater are
well tightened,
tube straps
without droping
off.
4.The material
used for fixing
part of tube clip
is correct.
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V Inspection of
supervision sampling
tube

1.The cutting position of supervision tube is
to be determined and recorded by the
chemical supervision personnel.
2.Cut the supervision tube with special
mechanical machine. The cutting point
should be deviated from tube clip and the
flex point of elbow for 150 mm. If such
position is last sample one, then the
replaced tube should also be removed. The
length of supervision arm should be more
than 250 mm.
3.After the removal of supervision tube, the
opening to the top should be plugged
immediately. Position, direction of fluid and
direction of gas side may be marked on the
supervision tube.
4.Measure the thickness of sampling tube
with thickness tester.
The cutting
position of
supervision tube
is correct.
There is no
damage to the
inner/outer wall
of supervision
tube.

VI Tube replacement

1. Following the cut of tube, use facing
machine to make the divided edge of cross
section.
2. Before butt welding, the pipe inner/outer
wall should be ground until showing proper
metal color. The length to be ground is
10-15mm in general.
3. Before the cut of new tube, visual
inspection and pipe thickness
measurement should be given to tube.
For curved tube, the ellipticity of bending
section should be carry out and given ball
passing test, if neccessary. Purge the
tube by the aid of compressed air before
butt welding. For alloy steel tube, spectrum
inspection should be performed before butt
welding.
4.The welding technology of tube should
meet the requirement of Technical
Specification of Electric Building
1.The divided
edges of tube are
smooth and flat.
The angle
machining of
edges is the
same with water
wall.
2.New tubes have
no traces of
cracks, erosion,
mechanical
damages, the
nagative
tolerance of tube
thickness should
be less than 1%
of tube
thickness. The
reduced amount
of thickness of
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Construction and Acceptanceweld section
of thermal power plant(DLS007-92).
5.If number of replaced tubes exdeeds 50%
of total, hydraulic pressure test should be
carried out.
curved tube
should be less
than 10% of tube
thickness. The
ellipticity should
be less than 6%.
The ball passing
test is qualified.
3.There is no dirt,
foreign matter in
the new tubes.
4.The flaw
detection to weld
seam following
the weld is
qualified.
2.4.3 Maintenance of platen superheater
Maintenance content: being same as above 2.4.2 maintenance of convection superheater
2.4.4 Maintenance of furnace top and enclosure superheater
The maintenance is the same as above 2.4.2 maintenance of convection superheater
2.4.5 Maintenance of convection reheater
I Ash cleaning of
heating surface

1. With compressed air, clean upside down
the ash deposits on the low temperature
superheater, tube surfaces of enclosure
superheater and horizontal gas duct.
2. Rinse the ash deposits on the surfaces of
tubes of separation platen superheater,
rear platem superheater and last stage
superheater.
3. When flush with water, protective work for
back stack well should be done to prevent
water entering the back stack well.
4. When blow coke around the enclosure
superheater, coke blocks should be
1. No ash deposit
and coking on
heating surfaces
of tube.
2. There is no
coking and other
foreign matter
between tube
rows.

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broken with hammer for further cleaning.
Note: Do not damage the tube.
II Anti-wear
inspection of tube for
heat absortpion

1. Pay more attention to inspect the straight
tube section of low temperature
superheater tube row on both sides of
suspended tube, 90elbow of upper/lower
connection tube, elbow of upper/lower
tube rows close to the back enclosure, and
tubes with the blow range of blower. If
worn tube is found, then measure the
thickness of tube with thickness tester.
And separately spot check two tubes to
measure and record tube thickness.
2. Emphasisly check the contact section of
platen superheater and horizontal position
tube, tube of last stage superheater
deformed tube row, tubes within the range
of blow of blower. If worn tube is found,
then measure the thickness of tube with
thickness tester. Also spot check and
record tube thickness.
3. Check the rear enclosure tube at gas inlet
section of low temperature superheater
and economizer, and enclosure tube
around the blow hole of blower.
The reduced
thickness of tube
should be less
than 30% of tube
thickness.

III Creep expansion
inspection of tube at
tube heat absorption
area

1. With slide caliper or pipe caliper, measure
the tube diameter of lead tube of low
temperature superheater, outer tubes of
separation platen superheater, outer
tubes of rear platen and the first tube at
flame-facing side of last stage
superheater.
Note that before measurement, clean the
ash deposits on the surface of tube and
coke attaching to the surface of tube.
During measuring, the slide caliper should
1. The expansion
value of carbon
steel tube of
superheater is
less than 3.5% of
tube diameter.
2. The expansion
value of alloy
steel tube of
superheater is
less than 2.5% of
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be perpendicular to tube.
2. Macroscopic inspection of the appearance
of tube.
tube diameter.
3. The appearance
of tube has no
obvious color
variation.
4. There is no crack
on the surface of
tube, and the
thickness of oxide
skin should be
less than 0.6 mm.
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IV Inspection and
reshaping of tube
row

1.Check the flatness and transversal pitch of
tube row. If deflection or curving exist to
tube row, find the reason of distortion or
the deformation points. According to the
reason, change the tube clip, restore the
flatness of tube row. For serious deformed
tube rows or single deformed tube deviate
from tube row, the deformed section
should be cut away to restore the origin
pitch and flatness, and then recover by the
aid of new tube. Change the transversal
live connection board of deformed tube
row, retighten the connection of platen
superheater and horizontal location arm to
restore the transversal pitch of tube row.
2. When replacing the tube clip or strap,
electric weld or grinder may be used to cut
the original parts. Note, do not damage
the tube when carry out cutting. Before
welding of fixing block of tube clip and
strap, grind the crator left on the tube.
3.When replacing the tube clip, be sure not
to weld the clip and tube together,
similarly, the tube straps can not be weld
each other when to be replaced.
4.The material of fixing parts should be the
same to that of original parts.
1.The tube rows are
flat, and
transversal
pitches are even.
2.The tube clip, tube
strap and
transversal live
connection board
of tube row are
sound, without
shedding, burning
out, deformation,
they are well fixed
to tube row and
can freely expand
with tube.
3.Horizontal
locating tube and
platen
superheater are
well tightened,
tube straps
without droping
off.
4.The material used
for fixing part of
tube clip is
correct.
V Inspection of
supervision sampling
tube

1.The cutting position of supervision tube is
to be determined and recorded by the
chemical supervision personel.
2.Cut the supervision tube with special
mechanical machine. The cutting point
should be deviated from tube clip and the
flex point of elbow for 150 mm. If such
position is last sample one, then the
replaced tube should also be removed.
The length of supervision arm should be
more than 250 mm.
The cutting
position of
supervision tube
is correct.
There is no damage
to the inner/outer
wall of
supervision tube.

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3.After the removal of supervision tube, the
opening to the top should be plugged
immediately. Position, direction of fluid
and direction of gas side may be marked
on the supervision tube.
4.Measure the thickness of sampling tube

VI Tube replacement

1. Following the tube cut, use facing
machine to make the divided edge of
cross section.
2. Before butt welding, the pipe inner/outer
wall should be ground until showing
proper metal color. The length to be
ground is 10-15mm in general.
section should be carry out and given ball
passing test, if neccessary. Purge the
tube by the aid of compressed air before
butt welding. For alloy steel tube,
spectrum inspection should be performed
before butt welding.
4.The welding technology of tube should
meet the requirement of Technical
Specification of Electric Building
Construction and Acceptance weld
section of thermal power
plant(DLS007-92).
5.If number of replaced tubes exdeeds 50%
of total, hydraulic pressure test should be
carried out.
1.The divided edges
of tube are
smooth and flat.
The angle
machining of
edges is the same
with water wall.
2.New tubes have
no traces of
cracks, erosion,
mechanical
damages, the
nagative
tolerance of tube
thickness should
be less than 1%
of tube thickness.
The reduced
amount of
thickness of
curved tube
should be less
than 10% of tube
thickness. The
ellipticity should
be less than 6%.
The ball passing
test is qualified.
3.There is no dirt,
foreign matter in
the new tubes.
4.The flaw detection
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to weld seam
following the weld
is qualified.
2.4.6 Maintenance of radiant reheater
(Same as above: convection reheater)
2.4.7 Maintenance of platen reheater
(Same as above: convection reheater)
2.4.8 Maintenance of header
Inspection of header

1.Spot check the fillet weld of tube
seat of header. Prior to check, grind
the weld and header surface around
the weld with electric wire brush until
showing the original metal color. For
tube fillet weld appearing
exceptions, flaw detection should be
performed.
2.For differential steel weld of
tube-seat of header tube row, flaw
detection should be performed after
100,000 h operation. Before
detection, grinder should be used to
polish the surface of and around the
sides of weld.
3.The header joint weld can be ground
or given flaw detection according to
the requirement of metal supervision
personnel.
4.The curveness of header may be
measured with method of wire
drawing. Prior to measurement,
choose 6 equalized points along
both sides of header. Mesure 6
values at such 6 points, select the
1.The fillet weld of
tube seat has no
cracks, the
differential steel
weld has no
cracks.
2.The repair weld
has no undercut.
3.The bending value
of header will not
exceed L/1000 (L
is length of
header), the
allowed maximum
is 5 mm.
4.The suspend
derrick is even
loaded, without
erosion or
deformation.

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minimum and record the direction of
this value.
5.For weld appearing cracks, eliminate
the cracks at first, and carry out
repair weld. For alloy steel tube,
preheat before weld and post heat
treatment will be adopted.
2.5 Economizer
2.5.1 Technical specification of economizer tube, economizer header
No. Item Unit Quantity
1. Economizer
Quantity 1
Transversal gas flow mm 102
Along the flow direction mm 96.6
Effective heat absorption area (gas side) m
2
3580
2.
Header of economizer
Should be
announced

Length m
around
17.2/15.7
Material SA106C
3. Water feed pipe-economizer to drum
Quantity 2
Nominal outer diameter mm 273
Material SA106C
2.5.2 Maintenance of economizer
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I Ash cleaning of
economizer

1. During the ash cleaning, a group of
induced fan may be started to keep
certain negative pressure in the furnace
and flue.
2.Upside down, purge and clean the ash
deposit on the surface of tube and tube
clip with compressed air.
3.The fouling in the ash hopper of
economizer should be cleaned and
drained.
4. Special processing measures may be
worked out when clean ash with water.
1.There is no ash
deposit on the
surface of tube,
and no foreign
matter between
tube row.
2.No ash deposit in
ash hopper of
economizer, ash
hopper is
free-flowing.
II Visual inspection of
economizer

1. Measure with thickness tester the wall
thickness of straight phase and bending
section of the tube row at both sides of
tube clip.
2. Measure the thickness of tube within the
blowing range of blower with thickness
tester.
3.Measure the thickness of suspended
tube close to the tube row.
4. Before measurement of tube thickness,
clean the ash on the surface of tube at
the area to be measured.
5. Check the transversal pitches of tube
row, eliminate the gas corridor.
1. The reduced
thickness of worn
or
blowing-damage
tube should be
less than 30%
tube thickness.
2. The tube rows
are flat, and
transversal
pitches are even.
No deformation or
loose weld with
tube clip.
3.The tube row is
flat, without
protruding or gas
corridor.
III Sample of
supervision tube

1. The cutting position of supervision tube
is to be determined and recorded by the
chemical supervision personnel.
2. Cut the supervision tube with special
mechanical machine. If such position
is last sample one, then the replaced
tube should also be removed. The
length of supervision arm should be
1. The cutting
position of
supervision tube
is correct. The
cutting point
should be
deviated from
tube clip and the
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more than 250 mm.
3. After the removal of supervision tube,
the opening to the top should be
plugged immediately. Position, direction
of fluid and direction of gas side may be
marked on the supervision tube.
4. Measure the thickness of sampling tube
flex point of elbow
for 150 mm.
2. There is no
damage to the
inner/outer wall of
supervision tube.
IV Tube
replacement

1. Following the cut of tube, use facing
machine to make the divided edge of
cross section; Before butt welding, the
pipe inner/outer wall should be ground
until showing proper metal color. The
length to be ground is 10-15mm in
general.
section should be carry out and given
ball passing test
3. Purge the tube by the aid of
compressed air before welding. When
carrying out the welding, 3 mm gap
should be left between tubes. The
welding of tube should adopt all argon
arc weld or technology of taking the
argon arc weld as the backing, electric
weld as the covering.
Note: Do not butt weld forcely. After the
tack weld, not to strike with hammer.
4. Following the weld, carry out flaw
detection to the tube.
1. The divided
edges of tube are
smooth and flat.
The machining of
divided edges
refers to that of
water wall.
2.The tube butt
welding should
refer to that of
water wall.
3. New tubes have
no traces of
cracks, erosion,
mechanical
damagesThe
nagative
tolerance of tube
thickness should
be less than 10%
of tube thickness.
The reduced
amount of
thickness of
curved tube
should be less
than 10% of tube
thickness. The
ellipticity should
be less than 6%.
The ball passing
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test is qualified.
4. There is no dirt,
foreign matter in
the new tubes.
5. The flaw
detection to weld
seam following
the weld is
qualified.
V Emergency
maintenance of
economizer

1. Following the stop of furnace and
pressure relief, ventilation should be
kept in the flue, but the water in the
economizer should be kept.
2. Only when the temperature in the flue
decrease below permitted maintenance
temperature, personnel can enter the
flue to find the leakage points. To find
the leakage tube, water trace, voice and
ash deposit of tube row or other
methods may be referred to confirm the
correct leakage section.
3. After determining the leakage position,
report it to the operation personnel to
drain the water in the economizer, and
separate the economizer system.
4. For the maintenance, methods such as
transfer tube section, short cut
connection pipe, can be adopted. Repair
weld may be used for tube which has
reduced thickness less than 30% of tube
thickness.
5.Following the weld, hydraulic pressure
test should be performed.
6.The ash deposit on the surface of tube
row should be cleaned before cutting.
After the welding the tube, ash deposit
and foreign matter in the ash hopper
1.The weld seam
undergoing
emergency
maintenance
have no leakage
(after hydraulic
pressure test).
2.There is no ash
deposit, foreign
matter in the ash
hopper, which will
keep free-flowing.

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should be cleared up and dredged.
2.6 Burner
2.6.1 Technical specification of burner
Oil burner: There are 8 HFO burner at each nose, i.e., 16 burners equipped for each boiler.The
auxiliary steam of which the pressure stablized as 5.25 bar(g) render the HFO into atomizing
state. Such steam is also used for burner purging. HFO will be ignited by high-energy ignitor.
Each HFO burner is equipped with special flame inspector. Cooling air is supplied to burner and
flame inspector through two independent special circuit. During the ceasation, the burner
withdraw from the burner nozzle for about 330 mm, in order to avoid the affection of boiler
radiation( prevent from burn out the burner). The total oil burning capacity (LHV base value) is
30% of BMCR fuel heat input value. Only adopting 12 burners can attain 30% of the burining
capacity of BMCR.( two burners of each nose stop operation). The adjustment ratio of burner is
1:5. J11 type burner is used.
2.6.2 Maintenance of burner
Maintenanc
e item
1.
Inspection
and repair
of burners

1. Prior to inspection, coking and ash deposits in
the nozzle and its outlet should be cleared up.
2. Check the surface wearing, surface split and
weld cracks of structural parts for primary air
nozzle.
3.Check the wearing and positioning conditions of
divergent cone of primary air nozzle and
pulverized coal dense/thin separation plate at
outlet of nozzle.
4. Check the wear of pulverized coal nozzle at the
outlet of primary air nozzle.
5. Check the appearance of secondary air nozzle.
6. Th local burn out, appearing in the nozzle can
be cut and replaecd locally with plasma cutting
machine. Divided edges should be machined
for repair weld, with the edge angle of 90.
Between steel plates, there should be left 2-3
mm gap.
7. Local wears appear on pulverized coal
dense/thin separation plate and nozzle can be
1.There is no coking,
ash deposit in the
nozzle and its outlet.
2.The primary and
secondary nozzles
are sound, without
serious wear, burning
out deformation, and
cracks.
3.The divergent cone of
primary air nozzle
and pulverized coal
separation plate and
pulverized coal
nozzle have no
serious wear; Cone
plate and separation
plate are well fixed.
4.After local repair weld
to nozzle, the surface
is flat, weld is abreast
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bead welded. with steel plate.
5. Following local repair
weld of the
separation plate, the
weld is flat.
2.Verificati
on of
burner
nozzle
swing
angle

1.Before the verification of nozzle swing angle, use
the chain hoist to swing nozzle at each corner,
observing the swing circustances upside down,
adjust the connection pole nut, to make the
synchronous swing of nozzles.
2.Adjust the regulation nut of control mechanism,
measure the level perpendicularity of each
nozzle, position the nozzle to horizontal level.
3.Swing the nozzle to the largest elevation and
inclination state, meauring the anlge value of
them.
4. According to the real position of nozzle, check
and calibrate the local indicator of swing anlge
of nozzle.
1. The swing of nozzle
is smooth. The swing
of nozzles keep
synchronous.
2.The tolerance after
the calibration should
be less than 0.5.
3.The actual swing
angle of nozzle
should be in
conformity with the
indiction of local
angle meter.
3.Baffle of
secondary
air
1.Separate the baffle crank with the piston of
pneumatic actuator, remove the crank, replace
the seal material of baffle axis.
2.Lubricate the battle until obtaining the flexibility.
3.Operate the crank to examine the close position
and utmost position.
4.Check the connection and fixing conditiono
baffle and axis.
1.The switch of baffle
turns smooth.
2.The position of baffle
switch is correct.
3.The appearance of
baffle is sound, and it
is well fixed with axis.
2.7 Rotary Air Preheater
2.7.1 Technical specification of rotary air preheater
Designation Parameters of specification

Preheater
Manufacturer
Type
Unit/Boiler
Shanghai Boiler Works, Ltd.
Ljungstrom trisector
2 unit/boiler
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Rotor: Diameter
height
Heat transfer element:
Material
Specification
10.318 m
1.88m
Primary section Cotton steel, Final section SPCC-SD
Thickness of Primary section, 1.2mm, final section,
0.6mm

Drive
device
Main motor
Secondary motor
Reduction gearbox
Reduction ratio
Rotor speed: Main drive
Secondary drive
Lubricant
Y180M-4B3, 18.5kW, 1470r/min
Y160L-8B3, Dual output axil 6.08kW, 720r/min
SGW100
128.3
11.46r/min
5.61r/min
ESSO Spartan EP150 Industrial Super Gear Oil (ISO
VG150): about 50L
Rotor
bearing
component
thrust bearing
component
Guide bearing
component
Lubricant
90394/710
3153172
ESSO Spartan EP680 Industrial Super Gear Oil
(ISO VG680):Thrust beaing 160L; Guide bearing 25L
2.7.2 Maintenance of rotary air preheater
I Familiar with
equipment
Learn the structure of air preheater, various
parameter features and technical
requirements.
Completely
correct
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II Refer to files

1. Find out the operation circumstances of air
preheater:
(1) Flaw, exceptions and emergency
circumstances finding in the operation.
(2) Inlet/outlet gas temperature, primary,
secondary air temperature at inlet/outlet.
(3)Air, gas resistence value of air preheater and
the variation circumstances.
(4)The current value and current swing value of
drive motor during the operation.
(5)Axial and radial runout circumstances of
rotor during the operation.
(6)Operation circumstances of bearing
component and lubricant system.
(7) Refer to test material and records, learn air
leakage, ash clog circumstances of air
preheater (an air leakage test may be
separately performed prior to and after the
maintenance).
2. Learn the maintenance circumstance about
air preheater:
(1)Summary of last maintenance, air leakage
materical and technical archive.
(2) Routine maintenance records.
(3) Ash cleanig, flushing conditions.

III Air preheater
maintenance and
technical,
organizational
measure plan
preparation
Main contents are as follows:
1. Maintenance content and items.
2. Personnel organization and labor division.
3. Construction network schedule.
4. Working safety and health protection
measure.
5.Quality guarantee and technical measures
6.Schedule of main facilities and tools, main

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IV Construction field
requirement
1. Sufficient place should be supplied for
maintenance of air preheater. Enough
construction power supply and lighting for
maintenance field, 12V lighting power
supply should be ready for entry the
preheater.
2.There should be setting mangement
schedule.
3. Sufficient fire fighting facilities should be
equipped.

V Safety The safety requirements of construction
should comply with the provision of Safe
Operation Regulation of Electric
Industry(Thermal Machinery Section).

2.7.2.1 Maintenance of heat transfer elements
Maintenance item Workmanship and precautions Quality
spare part, accessaries and list of major
materials.
7.Maintenance technology card
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standard
I purge of heat transfer
elements

When the ash deposit is slight (it can be judged
by experience according to the resistence
increase of air, gas in the preheater, combining
with attribute of ash that result from the coal
being fired), while can not clear up the ash
deposit only depend on the fixed ash blowing
facilities, compressed air (with pressure
1.2-1.3MPa) can be used to purge the heat
transfer surface, rotor surface and air, gas duct
after the stop of air preheater. The purge work
follows the sequence of from bottom to top,
then from top to bottom. During the blowing,
open all baffles of feed, induce fan, to allow the
boiler keep certain negative pressure, keeping
the good ventilation of air preheater.

II Washing of heat
transfer element

1. Destination of cleaning the heat transfer
elements: when the ash layer on the surfaced of
elements is hard to purge, flush it with water
that require certain quality demand.( usually,
flush with alkaline water in 60-80 and rinse
with water) The washing should be in the
state of furnace stop, and having enough
flushing and drying time.
2. Before the washing of heat transfer element,
the following work should be performed:
(1) Verify the degree of ash depositing according to
the maintenance records, operation conditions of
air preheater.
(2)Choose water cleaning method according to
depositing degree:
When the ash i s soft and has high solubility,
fixed washing equipment can be used to clean ( the
matching equipment supplied by manufacturer or
the flushing pipe from manufacturer served with
water supply of power plant).
When the ash deposit is hard having low
solubility, some high pressure washing equipment
Whichever
method is
adopted, if the
heat transfer
elements are
to be cleaned,
they must be
completely
washed, and
until the
thorough dry
of them.

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may be used for clean.
When the ash deposit is very hard or even being
the type of sintering, which is hard to clean with water,
the heat transfer elements box may be disassembled
for clean.
(3) Ensure the normal operation of drive device of air
preheater.
(4) Ensure the normal work of flushing device and
sufficient water supply.
(5) The boiler is stopped, and forced draft and
induced draft fans stop operation. Cleaning heat
transfer elements with single draft fan operating is not
recommended.
3. Cleaning method
(1) Washing with fixed rinsing device;
The washing job is better to start when the gas
temperature at inlet of air preheater decreases to
200 ( to prevent the permanent deformation, the gas
temperature is required below 200 ), and to
terminate before 80 .
Prior to cleaning, the ash in the h opper of air
preheater should be discharged.
During the flush, stop all the forced draft, induced
draft fan.
In the cleaning process, secondary drive device
should be employed to keep the air preheater run at
low speed.
The temperature of cleaning w ater is preferred to
be 60 ~80 .
If the deposits are acidic, defined amount of
sodium hydroxide or other alkaline substance (pH
value >11 ) may be added to the water to increase the
washing result.
During the washing, draining pipes must be
ensured to be free-flowing.

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III Inspection of heat
transfer elements

Rinsing pressure and flow rate: water pressure at
primary secton > 0.52 MPa; the flow rater of each
rinsing probe is about 150t/h.
Alternatively rinse the heat transfer elements at
primary and final section following the sequence of
primary section to final section. When the rinsing
pressure and water amount can meet the demand,
the washing work at both ends may be performed at
same time; discontinuned rinsing may also be taken
to allow the softening of deposits.
In the process, chec k the draining regularly.
When the pH difference is less than 1, or when the
rinsing water is common water, the pH value of
draining water is within 6-8, stop the washing.
Completing the rinsing, close the water supply,
after making sure the valve has no leakage, close the
draining valve.
After the rinsing work, immediately carry out the
job of drying the heat transfer elements. During the
drying, keep the rotating of air preheater, totally stop
the forced draft fan and induced draft fan, fully open
the air, gas baffles of inlet/outlet of air preheater.
Adopting natural ventilation, dry the heat transfer
elements with residual heat of boiler and air
ventilation. It must be make sure that all the heat
transfer elements is completely dried.
The rinsing result of heat transfer elements.
Draw out some typical heat transfer elements from
each layer. Take them down to check whether every
surface of the elements has ash deposit and
sediment or not. And ensure the completely dry of
them, i.e. being qualified. Otherwise, they are more
inclining to accumulate ash.
(2) Washing with special rinsing machine: when
regular rinsing machine is hard to clean the ash
deposit, special rinsing machine may be used to
washing the equipment after cooling of boiler.
Choose suitable rinsing pressure and water flow

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IV Replacement of heat
transfer element
rate according to actual conditions of ash deposit.
Using common water or alkaline water of which
the pH>11.
If the cleaning quality or the operation safety can
not be ensured inside the air preheater, the heat
transfer elements boxes should be lifted from the
sector cell to washing outside, until they are clean.
If rinse with alkaline water (pH>11), common
water may be used for washing the equipment again.
Following the rinse, pay attention to the drying of
heat
(3) Heat transfer element cleaning after
disassembly.
When the ash deposit on heat transfer elements
is sintered and hard to clean with water, the heat
transfer element boxes should be disassembled to
clean the surface deposit with mechanical method
and then reassemble them.
When the number or shape of heat transfer
elements can not be restored to the same of origin,
reasonable heat transfer elements should be
arranged perfectly according to the design of
manufacturer. Do not change the gaps between heat
transfer elements and the number of them, to avoid
affecting the performance of air preheater.
(4)The inspection of heat transfer elements should
include inspection of heat transfer elements and the
boxes of them, which are as follows:
Inspection of erosion, wear and deformation of
heat transfer elements.
Check the wall thickness of heat transfer
elements, measure them if necessary.
Inspection of heat transfer elements combination,
the corrugated plates and position plates should
keep the correct geometry shape; the corrugated
plate and position plate should be compressed.

The
replacement
of heat
transfer
elements
must ensure
the correct
geometric
shape and
quantity
combination.

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Except the special design provision that some nature
empty space exists, there should be not any
looseness. Otherwise corrugated plate or position
plate should be considered to plug in.
Inspection of erosion, wear, cracks, shedding,
deformation of frame of heat transfer elements. Put
emphasis on the check of cracks and fatigue
conditions of welding parts of such frames. If
necessary, repair the frames.
Inspection of support frame of h eat transfer
elements. Support frame have no deformation,
serious wear, no cracks on the weld seam.
Inspection of the gaps of heat transfer element
boxes edges and sector bin edges. Such gaps
should comply with the design requirement, i.e., less
than 3 mm.
(5) When one of the following circumtances
happens, the heat transfer elements should be
replaced( as the case may be, locally or totally):
When the erosion or wearing of heat transfer
elements is serious, affecting the heat transfer
result or operation safety.
Whn the wall thickness of heat transfer element
reduced to 1/3 original thickness.
seriously blocked, and can not be purged.
2.7.2.2 Maintenance of driving device
2.7.2.2.1 Maintenance of primary reduction gearbox
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1. Drain the lubricating oil and
check it; the disassembly of
shaft series parts should be
limited by clean and inspection,
try to reduce the disassebling
work; if it is need to take down
parts, the assembling marks
should be made; in no way
should the cotton waste be used
for clean parts.
1. The quality of gears,
shafts and bearings
should meet the provision
of related standards.
2. After the assembly of
shafts, the end face
dislocation of two engaged
gears at the direction of
face width should not
exceed the provision in
Table 1.
Table 1 End face
dislocation of two engaged
gears at the direction of face
width(mm)
Face
width( width
of rim)
End face
dislocation
I Disassembling clean
and inspection of all
parts

<50
50-150
1.5
2.5
II Inspection of oil level
gauge
1. Wash the oil level gauge with
kerosene.
1. Oil level gauge has no
damage, oil level shows
clearly, the mark of oil
level is correct.
III wash and inspection
of gearbox case
1. After the washing of case, wipe
the case with white cloth, and
stick the foreign matters with
adhesive object. Prior to
assembly, the inner space of
case should be kept clean.
Check with 0.05 mm filler gauge
the gaps of joint surface that
case seat and cover combined
freely.
1. The case has no cracks
and other flaws, and is
clean; the case has no
leakage; when the case
seat and cover combine
freely, the plug depth
should not more than 1/3
of joint surface width.
After compress the case
seat and cover, the seal of
reduction gearbox must
be tight, without leakage
or penetration of oil.
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IV Maintenance of
hydraulic coupling and
Replacement of shaft
gland
1. Check if the inner oil filling
amount meet the design
requirement of manufacturer, and
examine or replace.
2. Check the locking of screws.
3. Determine whether or not to
replace, according the the oil
penetration of shaft gland.
1. The shaft glands are well
without flaw.

V Replacement of
lubricating oil
1. Before oiling, consider whether
or not to filter oil according to
the quality of oil.
1. Oil quality meets the
requirement of
manufacturer.
VI Inspection of base
and screws of base
1. The base has no cracks,
the screws have no loose.
VII Assembly of whole
machine

1. During the assembly the gear
backlash and axial clearance of
bearing should meet the
requirements.
2. Adhesive must be add to the
joint surfaces, baffles of
upper/lower case, joint
surfaces, plug screw, oil scale
which adopt the paronite as
gasket. Surfaces are to cleaned
before coating.
1. The gear backlash is
0.21-0.40 mm; the axial
clearance of bearings
through which the shaft
protrude may be left at the
lower end, the value is
0.10-0.20 mm.
The axial clearances of shaft
I and shaft VII are left to
the side close to motor,
the value is 0.05-0.13 mm;
that of shaft III is
0.06-0.15mm the
clearance of other shafts
may be 0.05-0.13 mm.
2. After finish the assembly,
run the machine with
hand, the direction should
be correct, smooth and
easy, without clogging(the
numbering of shafts
based on manufacturing
drawings).

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VIII Trial operation

1. Following the assembly, no load
running must be carry out in the
direction of working, the normal
running time should be more
than 2h.
2. Load test, the time is 50h.
No load running should
meet the following
requirements:
(1) The speed regulating
mechanism is flex,
accurate and reliable.
(2) The running is stable and
regular, with impaction
and exceptional noise.
(3) Various sealed section,
joints have no leakage,
penetration.
(4) the fastening parts,
connection parts have no
looseness.
(5) The temperature rising in
the oil tank is not more
than 35 , that of bearing
not more than 40 , the
max temperature of
bearing not more than
80 ( or meet the
requirement of
manufacturer). Comply
with the requirements of
manufacturing
specification.
2.7.2.2.2 Maintenance of overrunning clutch
Washing after disassebly, check the completeness, lubrication and sealing conditions of
various parts. The clutch should be stable and reliable, and can swiftly, completely on-off.
2.7.2.2.3 Maintenance of shroud band driving device
I Engagement
inspection of drive gear
and output shaft
1. If disassembly is necessary,
various joint surface should be
thoroughly washed.
1. the contact surfaces
between drive gears,
shafts, bushes are
smooth, without burr,
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stablizely matched.
II Inspection of drive
gears
1.Check the cracks, perform the
penetrant inspection if
necessary.
1. The drive gears have no
missing tooth or block, the
gear roots have no cracks;
replace the gear when the
wear amount arrive at 1/4.
III Inspection of drive
shroud band
1.Measure the wear amount of
shroud band pin with slide
caliper; measure the radial
runout at the end of shroud
band with micrometer.
1.The welds of drive shroud
have no cracks, the fixing
screws have no break,
looseness, shroud band
pin without looseness or
falling off; replace the pin
when the wear amount
arrive at 1/4; the radial
runout value should in line
with the regulation of
manufacturer.
IV Inspection of
engaging conditions of
drive gear with shroud
band pins

1. Rotate the rotor, find out the
most protruding point of shroud
band pin( at the direction of
rotor diameter), measure the
dimension c ( may use the filler
gauge), also find the axial most
protruding point, measure the
dimension of a and b; if
necessary, adjust with pads to
ensure the full engagement of
drive gear and shroud band pin.
1.As shown in Fig. 2-9, the
fixing gaps between
shroud band pin and drive
gear should meet the
regulation of equipment
technical files: Min. a is 13
mm; Min. c is 20 mm.
2. The drive gear and
shroud band pin is in line
contact, the axis of drive
gear must parallel to the
axis of shroud band pin.
V Inspection of drive
gear enclosure
1.the enclosure of drive gear
must be sound and secure.
2.7.2.2.4 Maintenance of thrust bearing component and guide bearing component
I Measure and adjust
the levelness of
bearing block
1.The measurement of levelness
of bearing block should be
carried out at the direction of
end face diameter of the seat.
1.The error of bearing block
levelness is not more than
0.05mm.
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Record the data before and
after the maintenance.
II Disassembling
Maintenance of
bearing component
1. Prior to disassembly of bearing
component, drain the lubricating
oil in the seat; Implement the
temporary support and fixing
work of the rotor, keep the level
of rotor when supports it;
perform various record work
before the disassembly; during
the performance of bearing
component maintenance or
maintenance of other items of
air preheater, measures should
be taken to prevent the current
flowing through bearing,
avoiding the electric corrosion
at rotating objects.
2. Inspection of fixing bolts, nuts
and washers of bearing block:
The screws, bolt hole and
washers should be numbered
for the future reassembly that
mount parts with corresponding
number; during the assembling,
anti-seize paste should be
smeared between screw and
nut.
3.Inspection and washing of
bearing block Wash the bearing
block with kerosene, and stick
foreign matters with adhesive
object, and wipe it with lint-free
clean soft cloth.
4.Inspection and washing of
rolling bearing If the bearing is
needed to remove, hydraulic oil
pump may be used to remove
with compression; the bearings
1. The fixing screws, nuts
have no looseness; bolts
have no twisting, screws
and nuts have no
damaged tooth; washers
is tidy, without cracks;
bolts, nuts and washers
should be clean; when all
the nuts is fastened, the
washers should be
jammed together. Use
0.05 mm filler gauge to
check whether or not exist
gaps.
2. The bearing block has no
cracks, burr, groove trace,
rust, oily dirt, foreign
matter; the joint surface of
flange is purged clean,
without burr. There is no
shedding, falling off,
wearing, color variation
due to overheat, rust,
crack, or breaks; the
clearance of bearing
should meet related
requirement of standard.
3. The surface of rotary disc
is smooth, without pitting,
pinhole porosity, cracks,
groove trace; the balance
weight and position pin is
well.
4.The surfaces of shaft,
connection sleeve and
locking cover have no
cracks, burr, groove trace,
color variation due to
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should be put on the smooth
plane covered with soft cloth for
maintenance; check the gap of
bearing with method of pressing
lead wires.
5. Wasing and inspection of
shafts, connection sleeve,
locking cover Remove the shaft
and connection sleeve adopting
the pressing of hydraulic oil
pump.
6. Check the fitting conditions
between bearing, connection
sleeve, shaft and locking cover.
7. Inspection of thermal
temperature measurement point
device.
8. Check and washing of oil level
gauge: wash with kerosene.
9.Change the lubricate oile: filter
the oil before oiling.
10. Sealing inspection of bearing
block: Check the joint surface of
the flange of bearing block with
0.05 mm filler gauge.
overheat; the screws of
locking cover has no
fracture; there is no
relative motion between
shaft, connection sleeve
and locking cover.
Regulate the gap between
bearing and connection
sleeve, gap between
connection sleeve and
shaft, the fixing of locking
cover, tight tension of
screws should comply
with prescription of
manufacturer.
5. Oil level gauge has no
damage, oil level shows
clear, the dimension of
level is correct. Following
the completing of bearing
component maintenance,
immediately fill in
lubricating oil compling
with requirement to the
top level.
6. When the flange of
bearing block freely
combined, the depth that
the filler gauge plugs into
the joint surface should
not more than 1/3 of total
width; after pressing of
bearing block and bearing
cover, the seal must be
tight, without leakage or
penetration of oil.
2.7.2.2.5 Maintenance of rotor and air, gas ducts
With respect to air preheater of which the drive elements rotate, the rotor refers to the
sector bin in which mounted the heat transfer elements forming by the radial baffle and
transversal baffle. When the air preheater is running, it rotates with the heat transfer elements.
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Maintenance of rotor and air, gas ducts:
I Measure the center
barrel and the
levelness of fitting
parts of end shaft
1.Perform the measure with
precision level gauge at the
header plate of center barrel or
the shaft of support end; if the
permitted levelness is exceeded,
adjust the direct bearing seat and
check again.
1.The error of levelness is
not more than 0.25 mm/m.
II Measure the
roundness of rotor
1. Measure the roundness of
upper/lower panel of shroud band
with dial gauge.
1. The difference between
maximun and minimum
4mm.
III Measure the
deviation of
upper/lower end
plate of rotor
1. Use dial gauge to measure the
deviation of upper/lower end plate
of rotor
1.The deviation value 4
mm.
IV Measure the
concentricity
deviation of rotor
with casing
1. Use dial gauge to measure the
concentricity deviation of rotor with
casing.
1. The deviation value 3
mm.
V Inspection of rotor
welds
1. Visual inspection, if necessary,
perform penetrant inspection to
welds.

1. The welds between radial
baffle and transversal
baffle, welds between
radial baffle and center
barrel have no crack,
welding beading, welding
flaw, and ensure that the
welds have enough
strength.
VI Check connection
screws between
sector bins of rotor
1. The connection screws
have no looseness, no
fracture.
VII Inspection of
sector bins of rotor
1. The sector bins have no
deformation. The radial
baffles and transversal
baffles form the sector bin
grid, the dimension
deviation of grid edgs is
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6 mm, diagonal deviation
is not more than 10 mm;
the surfaces of baffles are
smooth, without burr and
welding beading.
VIII Check the gap
between rotor outer
wall and inner wall of
gas duct
1. Rotate the rotor, take 3-4 points
on the inner wall of gas duct,
measure the gap value.
1.Such gaps must be even.
IX Inspection of the
air duct, support
frame of gas duct
1.The support frame which
is seriously worn and
eroded must be replaced;
the anti-wear tiles are
firmly welded; those tiles
worn more than 2/3
should be replaced.
2.7.2.2.6 Maintenance and adjustment of sealing devices
I Inspection and
adjustment of sealing
devices

1.Measure the three-direction (radial,
peripheral or bypass, axial) gap values
before the maintenance.
2.Check of sealing strips.
3.Inspection of T-steel.
4. Installation and adjustment of radial
sealing strips: perform the gap
adjustment by the aid of sealing
component having been aligned;
detailed steps may be in accordance
with the specification of manufacturer.
5. Installation and adjustment of axial
sealing strips ( see Fig. 2-10):
Regulate the gap by the aid of aligned
axial sealing component, detailed
steps refer to the specification of
manufacturer.
6. Installation and adjustment of
peripheral( bypass) sealing strips ( see
1. The sealing strips
should be perfect,
those that seriously
worn, deformed,
eroded should be
replaced.
2.The roundness
deviation value of
T-steel may not
more than 1.5 mm.
The assembling
sequence and
installing direction of
sealing strips, gap
compensation strips
and pressing plate
should be correct,
the screws should
be tightened; the
sealing clearance
and the specified
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Fig. 2-11, take trisector as an
example); When measure the value of
a and b, place the gap gauge on the
min radius section of T-steel, rotate the
rotor, measure and record every 30;
measure value of c and d at the same
time.
7. Inspect seal of center barrel.
8.Check stationary seal.
deviation value
should not be more
than 0.5 mm.
3. As shown in Fig.
2-10, the error of
values with specified
value is 0.5 mm.
As shown in Fig.
2-11, the error of
values with specified
value, 0.5 mm for a
and b, 3 mm for c, d.
Such values may
meet the design
requirement. The
stationary seal at
various places
should in line with
the design
requirement.
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II Inspection and
maintenance of air
leakage control
system

1. Prior to maintenance, cut the power
supply following the reset of sector
plate.
2. Clear up the ash deposit and foreign
matters around the sensors and
actuator, keep tidy around sensors and
actuator.
3. Check the sector plate.
4.Inspect the flatness of the end flange of
hot end of rotor.
5. Adjust the clearance of the radial
sealing strip and sector plate to meet
the technical requirement. The
adjusting method is as follows:
(l) After the preliminary fix (but not
fastening) of radial sealing strip and
flange, adjust the distance from every
sealing strip to flat ruler by means of
aligned sealing components and
sealing ruler, allow it meet the
technical requirement of the distance
from radial sealing strip and sector
plate, then tighten the radial sealing
strips.
(2)Make the upper edge of radial sealing
strip as the base, adjust the levelness
and height of each sector plate, to
allow the distance of radial sealing
strip and sector plate meet the
technical requirement.
5. Inspect and repair the detector and
sensor. When the thickness of sensor
petal is less than 3 mm, replace it.
6. Correct the detector to make it match
with the exterior indication and to be
correct.
7. Perform maintenance and repair to
actuator devices.
8. Following the completion of maintenance
of automatic control system, such system
should attain the design requirement after
commissioning.
1. The sector plates
have no
deformation, crack,
the surfaces have no
unevenness.
2. The rising/dropping
of sector plates
should be smooth,
without clogging,
and can reach
utmost limited
positions.
3.The fixing, adjusting
devices of sector
plates should be in
good order.
4. The planeness value
should not be more than
0.5 mm, the flange
surface should be
smooth.

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III Quality standard for
maintenance and
adjustment of sealing
device
1. From the startup of
boiler to the full load
operation, the sealing
devices should not
occur serious friction.
2.7.2.2.7 Maintenance of various secondary systems
I Lubricating oil system The maintenance of lubricating system
should include maintenance of oil tank, oil
pump, oil filter, heat exchanger, pipes, valves,
thermometer, pressure meter.
1. Clear up the ash, foreign matter around
the lubricating system.
2. Disassembling oil pump for
maintenance, when changing new pump or
motor, pay attention to the correct rotation
direction of them.
3. Inspect the ground screws of oil pump
and motor.
4. Disassemble the oil filter for washing,
replace filter strainer. When disassemble the
oil filter, also check if the reversing valve of
strainer can be closed tightly; Check and
wash the by-pass safety valve, and verify or
adjust the pressure.
5. Disassembly inspection of and washing
oil cooler, and perform the hydraulic pressure
test.
6. Inspection of various valves.
7. Check, wash the oil tanks, oil pipes,
eliminate leakage.
8. Washing and inspection of oil scale,
calibrate correctly.
9. Oiling, first filling to the top. When the
circulating oil pump put into operation, the oil
level may drop, observe the change of oil
1. The switching of
various valves of
pipes is smooth,
without leakage.
2.The joints of oil
pipes have no
leakage.
3.The indication is
clear, correct.
4.Lubricating oil and
strainer may be
change at least once
per year.
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level, and filling the system in time.
II Maintenance of fire
fighting system
1. Arrangement check of hose nozzles.
2. Check the wearing, erosion and blocking
conditions of fire-fighting pipe and nozzles,
and repair.
3. Check the free-flowing of fire-fighting
system, which should have no leakage.
4. Maintenance of the valves of fire-fighting
system.
5. To prevent of the block of hose nozzles,
heat-resist cellucotton plug or the anti-block
plug in other forms may be considered for
installing in the exit of nozzle.
1.The hose nozzles
should evenly cover
the heat transfer
elements at gas
side.
2. The nozzles, of
which the worn
thickness exceeds
2/3 of total must be
replaced.
3. Make certain that
various valves are
smooth, without
leakage.
III Maintenance of ash
blowing system
1. Maintenance of steamed ash blowing
system: Currently, the systems provided by
manufacuturers are all steamed ash blowing
ones. The whole system includes blower,
pipes, valves, instruments and ash-blowing
control system. The superheat degreee of
steam should be controlled strictly, and may
be put into use and maintained according to
prescription. Following are maintenance
contents:
Maintenance of soot blower
Check the blowing damage, erosion,
blocking deformation condition of barrel of
soot blower and nozzles, and repair;
Inspection and repair of drive devices;
Change lubricating oil;
The soot blowing barrel of retractable soot
blower is normal;
Change the sealing packing, eliminate
leakage.
Inspect steam pipes, eliminate leakage,
1. Make sure the
steam blower has no
clogging during
operation.
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check the steam pipe entering the air
preheater. The draining device at the
lowest section must be free-flowing.
Check and repair of various supports and
hangers and their insulation.
Maintenance of pressure reducing valve,
setting the pressure.
Maintenance of safety valve, setting the
pressure;
Calibrate the pressure gauge and
thermometer;
Maintenance and commissioning of soot
blowing control system.
IV Maintenance of
alarming system
1. Air preheater fire alarm.
2. Rotor stop rotating alarm
3. Bearing temperature supervision system.
1.When the infrared
measuring point
attains 150-200 ,
the annunciator
alarms.
2. When oil
temerature of
support bearing
reaches 71.1 ,
alarm.
3. When oil
temperature of
direction bearing
reaches 82.2 ,
alarm.
V Miscelleneous 1. The air preheater should be equipped
with seal-type sight glass
2. The holes and doors are in good
condition, their closure is tight.
3. All the platforms, handrails and railings
are good.
4. The insulation is in good condition.
1. Ensure the sight
glasses and
manholes are tightly
sealed, without
leakage.
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5. Various beams, posts are intact.
2.8 Desuperheater
2.8.1 Technical specification of desuperheater
Two water spray desuperheater stages are arranged for superheater system. The first stage
desuperheater is arranged at the connection pipe between low temperature superheater and
separation platen superheater, the nozzle adopts multihole flute-form tube structure, material
12Cr1MoV. The second stage water spraying desuperheater is arranged at the inlet connection
pipe of last-stage superheater, adopting multi-hole flute-form nozzle, material 12Cr1MoV.
2.8.2 Maintenance of desuperheater
I water spraying
desuperheater of
superheater
1. Clean with wire brush the rust
and fouling on the surface of and
around the position screws of inner
bushing and spraying pipe of
desuperheater, and welds of outer
wall spraying pipes and fixed
bushing of desuperheater header,
until showing the origin metal color,
and perform penetrant inspection to
such welds.
2. After operating for two overhaul
circles, the spraying pipes, sleeves
inside the desuperheater should be
checked with endoscope.
3. When spraying pipes are to be
replaced or multihole flute-form
nozzles are to be checked, the
connection weldd of spraying pipe
and fixed sleeve may be cut, and cut
the welds of position screws,
unscrew the position screw, at last,
cut the spraying pipe and take out.
Prior to installation of spraying pipe,
the direction of spraying hole should
be marked on the top of spraying
pipe. During the installation, it may
be fixed with position screws at first.
After confirm the correct direction of
1. The fastening screws of
inner bushing of
desuperheater, and
spraying pipes, position
screws and welds of outer
wall of desuperheater
header have no cracks.
2. The welds of feeding
pipe and fixed bushing of
desuperheater have no
crack.
3. The surfaces of inner
sleeve of desuperheater
have no erosion, crack, and
is well secured, the surfaces
of spraying pipe have no
crack, erosion.
4. After replacement of
spraying pipes, the direction
of spraying hole should be
correct, the welding of pipes
should meet the
requirement of Technical
Specification of Electric
Power Building
Construction", the welding
section of thermal power
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multihole nozzle fix the postion
screws and butt welding edges with
spot welding. Then weld them
separately. At last weld the spraying
pipes and fixed bushing. Before
weld, grind the inner/outer wall at
both ends of pipe, the ground length
may be 10 to 15 mm. The welding
will take the technique of with argon
arc weld as backing and electric
welding as cover, heat treatment
should be performed after welding.
plant (DL5007-92).
II Water spraying
desuperheater of
reheater
1. Remove the flange screws and
position screws of spraying pipe,
take out the nozzle.
2. Inspect the hole diameter of
nozzle and welds of it.
3. Check the inner wall of inner
sleeve of the desuperheater with
endoscope.
4. Prior to replacement of nozzle,
its direction mark should be made.
During the replacing, the joint
surface of flange should be tight, the
flange screws are even loaded.
1. The nozzles have no
blocking, welds of them
have no crack.
2. The surface of inner
sleeve of desuperheater has
no crack.
3. After replacement of
nozzle, its direction is
correct, the joint surface of
nozzle flange is well sealed.
2.9 Boiler Water Circulating Pump
2.9.1 Technical specification of boiler water circulating pump
Designation Specification Parameters
Type Oil seal free circulating pump
Work medium boiler water
Quantity per boiler 3 units
Number of operating pumps 2 units
Design pressure 2. 10MPa
Test pressure 3. 15MPa
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Design temperature High pressure cooling device: 176
Medium temperature Hot state:359 C Cold state: 20
Flow rate 2182mJ/h
Maximum temperature difference between
pump housing and boiler water
55K
Input power of pump Hot state:121.5kW Cold state: 225.5kW
Low pressure temperature cooling water Inlet: 37.8C Outlet: 45.5
Low pressure cooling water flow rate 5M3/H
2.9.2 Structure of boiler water circulating pump
The Boiler water circulating pump is a single-in-dual-out single stage centrifugal pump in
the circulation of boiler water. It consists of wet-type stator asynchronous motor and connected
pump component, pump housing and heat exchanger for cooling motor. Thereinto, the inlet and
outlet of pump housing are connected to downcomer system of boiler. In the cavity of pump,
there is an closed type diffuser driven by key and a mixed-flow impeller which is mounted on the
extension end of motor shaft. In the impeller and diffuser, wear-resist rings are equipped. The
motor is hanged on the pump housing, the motor and pump housing are connected with high
pressure sealing flange. To reduce the heat transfer from pump body to motor, the cross section
at the connection part of motor and pump is very small, such part is called neck. The motor
casing and pump are intergrated via the connection of neck. Separation plate is installed at the
connection section of pump and neck, to prevent the boiler water to the inner of motor. The heat
exchanger is arranged besides the motor. It forms a cooling circuit together with motor.
2.9.3 Maintenance of boiler water circulating pump
I Removal of
motor of boiler
water circulating
pump

1. Before the removal, number the screws,
nuts of the connection flange of pump/motor and
pump housing, and mark corresponding number
on the pump housing; Select 6 corresponding
equalized points at the two connection flanges,
measure and record the distances between 6
equalized points.
2. Mount two chain type lifting device or
rigging on the lifting eyes at both sides of
pump/motor. Before the loose of nuts of
fastening screws, pretight the pump/motor with
two lifting devices.
Note: Each lifting device should be able to bear

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all the weight of pump/motor.
3. Remove the high, low pressure cooling
pipes connected to cooler of pump/motor, and
block the exit of pipes.
4. Install heating rod or hydraulic tension
clamp for loosing the flange screws.
5. When heat with the heating rod, the
temperature can not exceed 300, the heating
time can not exceed 50 min. during the heating
process, tap the nuts with little hammer until the
looseness of screws, and can unscrew the
screws with hand, then stop heating.
6. When use the hydraulic tensioning device
for screws, firstly check the oil pump, which
must be well for use.
7. The pressure increase of oil pump should
be performed slowly. The pressure that each
screw bears should be uniform. The pressure
rise of oil pump can not exceed the limited the
working pressure. Use a little hammer tap the
screw at each sequencial pressure value, until
all the screws can be loosen with hand, then
stop pressure rising.
8. When all the nuts to the connection screws
of flange are removed, synchronously operate
the two lifting devices to make the pump/motor
to apart from the pump housing, and remove the
pump/motor from the pump housing.
Note: During the removing, keep the plane of
pump/motor in level, until the diffuser apart from
the pump housing.
9. Following the removal of pump/motor, it
should be put at clean maintenance place in
horizontal position.
Note: Do not place the weight at draining
valve or line connecting cover.
II Disassembly of 1. Prior to the removal of diffuser and impeller, 1. The key way at
shaft end and the key
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pump component they should be marked.
2. Dismount the hex bolts fixing the diffuser on
the motor, remove the diffuser.
3. Unscrew the jammed screws or nuts of
impeller, draw out the impeller from the shaft.
Then take out the screws of anti-wear ring of
impeller and the anti-wear ring.
Note: after remove the impeller, immediately use
a maintenance nut to protect the thread of shaft.
4. Clean the fouling on impeller, diffuser and
anti-wear ring with wire brush, brush or
compressed air, and inspect their surfaces.
have no damage.
2. There is no
fouling on the
surfaces of diffuser
impeller and blade.
3. The reduced wall
thickness of worn
trace of diffuser and
impeller is less than
30% of wall thickness.
4. The root section
of impeller has no
crack, the hardened
surface of anti-wear
ring is smooth without
cracks.
III Inspection of
sealing face, flange
screws, nuts of
pump housing.
1. Clear up and inspect the sealing face of
pump housing flange. If blowing damage or
erosive pitting exist on the sealing face, grind
them.
2. Wash the flange screws and nuts with
kerosene, also randomly select two screws and
nuts for penetrant inspection.
1. The sealing face
of pump housing
flange is flat and
smooth, without
blowing damage,
crack, erosion.
2. The threads of
flange screws and
nuts have no break,
burr.
3. The elongation
value of screw is less
than 0.3 mm.
IV Installation of
pump component
and pump/motor
1. Put the anti-wear ring on the baffle of
impeller and fix it, remove the thread protective
nut on the shaft end, mount the impeller key,
place the impeller onto the motor shaft.
Note: After complete the installation of impeller,
measure and adjust the concentricity of impeller
and motor shaft, anti-wear ring, the gap of motor
shaft of impeller, distance form impeller end face
to main flange plane at motor side.
1. The top gap of
impeller key should
be less than 0.25 mm.
2. The eccentricity
of impeller is less than
0.05 mm.
3. The distance
from end face of
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2. Put the diffuser on the motor bolts, align
with the position marks made during removal,
fasten with screws.
3. The lifting of pump/motor should be slow,
and keep the level when put the diffuser into the
pump housing. When the motor side flange
reach the bolts of pump housing flange, stop
raising. After all bolts align with holes on the
flange, lift again until the two flange sealing
faces contact. Then pretight with nuts. After that,
make corresponding position marks on the nuts
and screws.
Note: seal gasket of flange should be
replaced. Coat molybdenum disulfide on all
screws and nuts and flanges.
4. Install heating rod or hydraulic tensioning
devices for tightening the flange screws.
5. The heating should be carried out piece by
piece. Evenly distribute 8 items /piece. Heat
untile each nut can turns one whole circle( 24
scale intervals), and then cool down. Heat
another 8 bolts, until each nut can turn 2.5 scale
intervals.
6. In the employment of hydraulic tensioning
device, the tension pressure of each bolt should
be identical, tighten each nut at every sequential
pressure value.
7. Following the fastening of nuts, select 6
opposite bisection points at circumferences of
two flanges, and measure the distances of two
flanges.
impeller to flange face
of motor side should
have no deviation.
4. During the
installation of
pump/motor, the
diffuser and screws
and pump housing
should have no
collision; after
installation, seal face
is well contacted and
tight. The pump has
no leakage after
putting into operation.
5. The distance
error of two flanges
should be less than
0.06 mm.
V Maintenance of
heat exchanger
1. Remove the connection screws of
lower/upper side end cover flanges of heat
exchanger, take down the end cover.
2. Clear up the dirt on the surface of pipe
plate, and carry out flaw detection to such
surface.
3. Remove the fastening screws of filter
1. The pipe plate
has no dirt, thread.
2. The filter screen
has no damage, dirt.
3. No leakage
during the hydraulic
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screen, reverse blow the screen with
compressed air , and wash it in clear water.
4. Replae all sealing parts.
5. Disassembly of high pressure water filling
valve, replace the seal strip.
pressure test.
4. The sealing strip
of high-pressure
water filling valve has
no damage.
2.10 Hydraulic Pressure Test of Boiler
2.10.1 Classification of hydraulic pressure tests
Hydraulic pressure tests are divided into two kinds: one is normal hydraulic pressure test,
test pressure is working pressure of drum. Another kind is at when the boiler stopped for 1 year
and need restore the operation; or when the structure of boiler underwent major reforming, or
pressure equipment or system underwent major exceptions, the changed heating area
exceeding 50%, the drum or lower drum has major reforming; or when the safe reliability of
pressure equipment is doubted according to operation conditions the overpressure test is
needed. The test pressure is the value provided by manufacturer. If demand overpressure test
value, then take it according to 1.25 folds of the design pressure of drum.
2.10.2 Qualified Criteria of hydraulic pressure test
1) Pressure drop in 5 min: less than 0.5Mpa for primary system, less than 0.25Mpa for
secondary system;
2) There is no leakage trace of any beads or water fog on the metal wall of pressure barrier
parts and welds.
After visual inspection, the pressure parts have no obvious residual deformation.
2.10.3 Conditions of hydraulic pressure test
After the maintenance of boiler, to verify the quality of pressure equipment, and ensure
the boiler can be started in one time and the safety operation of pressure equipment, such
equipment should be given hydraulic pressure test following the maintenance of boiler heating
surface and steam and water system outside the boiler.
Normal pressure or overpressure test can be carried out only after the following works
have been finished:
1) The maintenance of boiler heating area and steam and water system outside the boiler are
completely finished.
2) Valves of steam and water pipes of boiler have been mounted, electric actuators have
been calibrated.
3) Maintenance of electric water feed pumps complete.
4) Main steam pipes are isolated from HP cylinder of ST, withou leakage.
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5) All pressure meters have been calibrated.
6) The local water gauge for drum and electric connection point water gauge have been
mounted and calibrated.
7) The TV camera for local water gauge of drum is normal.
8) The support/ suspension derricks for four kinds of pipes is ensured to be safe, and have
been reinforced when necessary.
2.10.4 Hydraulic pressure test
Preparation work
before hydraulic
pressure test
1. Fill out applicant sheet of hydraulic pressure
test. After the countersign, it should be sent to the
shift chief-operatorThe applicant sheet may
include:
(1) Hydraulic pressure test time
(2) Test range.
(3) Test pressure.
(4) Safety and protection measures.
(5)Exceptions of equipment within the hydraulic
pressure test range, exceptions completion report
and system diagram after exceptions.(6) Signature
of discipline principal and countersign principal. If
its overpressure test, the signation includes that of
General Engineer.
2. According to range of hydraulic pressure test
and the pressure of test, such equipment as
follows should be protected or separated:
(1) Safety valves. (2) Electromagnetic relief
valves.
(3) For supports and hangers of main steam pipe,
if the permitted load is not clear, then chain hoist
should be hung to the pipes or supports and
hangers and give pretightening, in order to avoid
the overload of supports and hangers.
3. Set out the technical measures and
organizational measures of hydraulic pressure
1. The hydraulic
applicant sheet is
correctly filled, without
missing.
2. Protection plates of
safety door are mounted
without omitting.
3. Organizational
measures and safety
measures are perfect.
Clearly specify the
director, coodinator,
inspector and test steps,
notes.
4. The needle of
expansion indicator is
adjusted to zero.
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test.
4. Check the guidance device of boiler
expansion and expansion indicator.
II Hydraulic
pressure test
1. Injecting water into boiler until the closure of
air gate.
2. Increase the pressure of boiler to 1MPa.
Carry out preliminary inspection to various
systems by inspectors.
3. If no exceptions is found during the
preliminary inspection of equipment and systems,
inform the operator to continue the pressure
increase. When the pressure increase to 4MPa,
stop pressure increase, and keep that pressure.
Tighten the screws of drum manhole and lower
drum manhole by the maintenance personnel.
Note: During the pressure increasing, the increase
rate should be less than 0.6 MPa/min.
4. After the tightening of manhole screws, inform
the operator to increase the pressure to test
pressure and keep it. Inspect the pressure
equipment and systems by the maintenance
personnel.
5. Record the values of various expansion
indication pannel.
1. Pressure pipes and
weld seam have no
leakage.
2. Pressure valve is
free of leakage.
3. Manholes of drum
and lower drum have no
leakage.
4. Pipes have no
residual deformation.
II Overpressure
test
1. The same as normal hydraulic pressure test.
2. As the test pressure increase to 5532,
inform the operation personel to stop increasing
the pressure, and keep that pressure.
3. The maintenance personnels enter the field to
check various pressure equipment and systems.
4. After confirm that the equipment and system
have no exceptions and maintenance personnels
withdrawn from the site, inform the operation
personnel to increase the boiler pressure to test
value, keep the value for 20 min, and then
decrease the pressure to normal work value.

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5. Connect the equipment that does not receive
overpressure test to the system.
6. The maintenance personnel enter the site
again to inspect pressure equipment.
7. After ensure that the equipment has no
exception, inform the operation personnel to
relieve the pressure.
Note: During the overpressure test of boiler, such
equipment as the safety valve, electromagnetic
valve, water gauge, boiler water circulating pump
etc. should be separate from the system.
2.11 Maintenance of Boiler Steel Frame, Platform Handrail and Manhole
2.11.1 Structure of boiler steel frame
The boiler is disposed open to air. Its structures mainly includes support posts and
suspending load beams. The support posts include 6 sysmetric steel frame upright post as
the core support, between the main posts, it's connected with cross beam, in order to add the
stability of steel beam.
2.11.2 Maintenance of Boiler Steel Frame, Platform Handrail and Manhole
Maintenance item Workmanship and
precautions
Quality standard
Inspection of steel
beam at top of
furnace
1. Measure with thin wire
the deflection of main
suspension beam and other
secondary beam.
2. Check the surface
erosion of beams.
3. Check the levelness of
transient beams and
suspension screws and nuts.
1. The deflection of main beams
should be less than 1/850.
2. The surface of beam has no
erosion, the surface of metal has no skin,
the painting is well.
3. The bending deformation on the
length of transint beam less than 5 mm,
the suspension screws is even loaded
and nuts have no looseness.
II Rigid beam
inspection
1. Inspect the straightness
of rigid beam.
2. Check the surface
erosion of rigid beam.
3. Check the weld between
rigid beam and connection
1. The rigid beam has no serious
deformation.
2. The surfaces of rigid beams have no
erosion, the metal has no skin.
3. The connection plate between rigid
beam and water wall has no cracks.
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plate of water wall.
4. Check the gap between
horizontal beam and vertical
rigid beam.
5. Check the corner
connection plate between
horizontal beam and vertical
rigid beam.
4. The gaps between horizontal beam
and vertical rigid beam are even, the
expansion is free.
5. The corner connection plate
between horizontal beam and vertical
rigid beam has no deformation and is
flex without clog.
III Inspection of
hangers of header
at heating area

1. Check the fillet welds of
lifting eyes of hangers of
headers at heating areas.
Clear the rust on the surfaces
of fillet weld before the check.
2. Check the straightness
and erosion of handger.
Swing the hanger with hand
to check the degree of
tightness.
3. Check the suspension
screws and base plates of
hangers.
1. The fillet welds of lifting eye have no
cracks.
2. The hangers has no deformation,
erosion and is evenly loaded.
3. The suspension nuts of hangers
have no looseness, the base plates have
no deformation.
IV Platform
handrail
Check whether the paddle of
handrail and connection
welds with platform or
connection screws is loose.
1. The hollow grid plate of platform is
flat, without loose welding or false
welding.
2. The handrails have no deformation,
erosion, they are securely welded,
without false welding or loose welding.
3. The connection welds of handrail to
the platform has no cracks, the pedal
plates have no deformation or
looseness. If its connection screw, no
looseness should exist.
V Manhole

1. Check the completeness
of insulation to door cover of
manhole and fire watching
hole.
2. Lubricate and loose the
1. The manhole, fire watching door is
tightly sealed after close.
2. The inside insulation lining of door
cover is complete, without cracks and
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hinges of manhole and fire
watching door until the
flexibility.
3. When replacing the
manhole and fire watching
door, lubricate the fixing
screws and nuts of frame for a
while, and remove the nuts.
After the mounting of frame, it
must be flat and tight.
falling off.
3. The switch of manhole and fire
watching door is flex, without clog.
2.12 Special Tools and Spare Parts and Material for Maintenance of Boiler Proper
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3 Valve, Water Level gauge, Pipe and Accessories
3.1 Maintenance of Safety Valve
3.1.1 Structure of Safety Valve
8 spring safety valves made by Crosby Company are equipped the boiler. The arrangement
positions are:
Drum 3
Superheater outlet pipe 1
Reheater inlet pipe 2
Reheater outlet pipe 2
A draining solenoid valve is installed on the superheater outlet pipe with a brand of VTI and
supplied by Crosby Company.
The setting pressure and discharge capacity of safety valve is in accordance with ASME.
The maximum evaporation of boiler is 995t/h and total discharge capacity of drum safety valve
is 881.796t/h, accounting to 88.62% of the maximum evaporation. Discharge capacity of
superheater safety valve is 153.86t/h, 15.46% of the maximum evaporation. The total discharge
capacity of drum and superheater safety valve is 1035.656t/h, 104.09% of the maximum
evaporation.
The maximum flow of reheat steam is 848.6t/h. the total discharge capacity of reheater inlet
safety valves is 512.94t/h, 60.45% of the maximum flow of reheat steam. Total discharge
capacity of reheater outlet safety valves is 379.157t/h, 44.68% of the maximum flow of reheat
steam. the total discharge capacity of reheater inlet and outlet safety valves is 892.097t/h,
105.13% of the maximum flow of reheat steam.
The discharge capacity of power-operated discharge valve is 166t/h, 16.68% of total
evaporation of boiler, which is not included in the discharge capacity of safety valve.
Safety valve is the major protection equipment for boiler equipment. When boiler pressure
exceeds allowable value, the inlet pressure of valve will increase so that the force applied on
the valve disc will be equal to or greater than the spring force. Then the disc will leave the close
position and the openness chock block will block the cover plate. The valve is to be at full open
position. Steam enters steam chamber H via two blow holes on the top of disc ring. Meanwhile,
stem overlapping ring will go up to the fixed position above the levitation gasket. The clearance
between levitation gasket and stem will increase because of enlarged diameter of overlapping
ring. Therefore steam in chamber H can enter steam chamber Q via the gap between levitation
gasket and overlapping ring and vent to the air through orifice and discharge pipe. When boiler
pressure drops to a safe value, the force applied by upper adjusting ring is lower than that of
spring at the discharge outlet of safety valve. Then the valve disc closes downwards and
overlapping ring will move downwards along with valve stem into the levitation gasket
effectively reducing the steam discharge of the steam chamber H. An instantaneous combined
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press force in the chamber H will push along with the flow direction of orifice and direction of
spring force ensuring the valve disc accurately close. The lower adjusting ring controls the
buffer of disc closing. Safety valve can effectively and accurately return to the close position
without damaging the valve disc and sealing surface.
Summary table of setting pressure and discharge capacity of safety valve
Setting pressure
Design
temperature
Serial
No.
Valve
type
Size
(inch)
jump up
MPa
reseat
MPa
Differential
return
pressure
%
Steam
discharge
t/h
Drum safety valve
1 HE-96W 3 M2
6
20.50 19.89 3 291.697 369
2 HE-96W 3 M2
6
20.60 19.78 4 293.924 369
3 HE-96W 3 M2
6
20.70 19.67 5 296.175 369
Superheater outlet safety valve
4
HCI-98W 3 L2
6
18.70 18.14 3 153.860 557
Reheater inlet safety valve
5 HCI-46W 6 RR10 4.50 4.37 3 253.574 313

6
HCI-46W
6 RR10 4.60 4.46 3 259.366 313
Reheater outlet safety valve:
7 HCI-48W 6 RR10 4.10 3.98 3 187.347 554
8 HCI-48W 6 RR10 4.20 4.07 3 191.810 554
Draining solenoid valve
9 E0L121N7BWRA5P1 2.54 18.50 18.13 2 166 557
3.1.2 Maintenance of safety valve
Maintenance
item
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Maintenance
item
(I) Maintenance
Preparation
1. Open vent valves of drum and other heating
equipment ensuring the pressure in drum or
other heating equipment is equal to ambient
before maintenance of safety valve.
2. Clean rusted matters in water-delivering pad
of steam discharge pipe.

(II) Disassembly 1. Remove operating lever pin and operating
lever on the top of valve, and loose valve cap
set screw of lift-gearing device, and then take
off valve cap and lower down operating lever
assembly.
2. Remove fixing pin of reset nut and turn out
reset nut.
3. Turn out gland nut from valve stem, and
clean dirt on the surface of gland screw with
blade cloth ; measure and record the distance
A between end surface of gland screw and top
of valve stem, refer to Fig 3-3.
Loose locking screw of the gland nut, and
loose gland nut by special wrench until it
separate from upper spring washer.
4. Turn out yoke bar nut and take off yoke
support.
Note: evenly turn out yoke bar nut to prevent
yoke bar and valve stem from bending. Take
out supporting assembly and top spring
gasket.
5. Mark original position at spring top, and take
out spring bottom gasket at spring bottom from
valve stem.
Note: if spring bottom is stuck to gasket;
separate them before removal of ring.
6. Mark on the notch of valve stem pin hole
located on the overlapping lantern ring, and
then rotate overlapping lantern ring
counterclockwise until the lowest one of four

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Maintenance
item
lines is on the same line of upper levitation
gasket. Count and record notches passing by
the valve stem pin hole. See Fig 3-4.
Make positioning marks on the cover plate and
vent hole, and remove stud nuts of cover plate
and take off cover plate.
7. Lift valve stem together with valve clack,
junk ring assembly out of valve body, and
horizontally put them in a clean area.
Note: during lifting and putting valve stem
together with valve clack, junk ring assembly,
do not crash them and ensure sealing surface
of valve clack undamaged.
8. Vertically erect valve stem and secure it.
Then lift junk ring and rotate it
counterclockwise to engage it with downwards
thread. Loose junk ring until take off valve
clack. Take out junk ring from valve stem.
Refer to Fig 3-50.
9. Remove pin of upper adjusting ring from
valve seat; vertically lift guidance; and take
out pin of upper adjusting ring and guidance
assembly; make an axial mark on the guidance
and pin of upper adjusting ring with marker,.
Refer to Fig 3-6; turn off pin of upper adjusting
ring from guidance.
Note: do not change the setting of pin of upper
adjusting ring.
10. Loose the pin of lower adjusting ring until
the notches of pin and ring separate slightly.
Place a plate on the top of sleeve seat, and
mark on the pin notch of the lower adjusting
ring, taking the pin as reference, rotate the
lower adjusting ring counterclockwise until the
ring contact with the plate. Count and record
the number of notches passing by the pin of
lower adjusting ring; turn off the lower adjusting
ring from valve seat sleeve and take it out from
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Maintenance
item
the valve body, see Fig 3-7.
Note: do not rotate the lower adjusting ring
during turning off the pin.
11. After removal of parts inside valve body,
install cover plate and stick strip seal on the
valve body to prevent dirt from entering.
Check the amount of parts after removal, and
put them into oil for washing. Then wipe up
them with clean blade cloth and put them at
specified location.
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Maintenance
item
(III) Check and
grinding of valve
clack, valve clack
junk ring and
guidance
1. Wipe up the valve clack, with a clean and
soft blade cloth; check its sealing surface,
internal thread and supporting surface.
2. Grind the valve clack with special
circle-shape grinding plate. Before usage, coat
the surface by grinding agent with #1000 mill
grains, and then grind on the grinding plate of
the standard plane until it is plain. Grinding can
be carried out as per Fig 3-8.
3. Wipe up the ground circle shape grinding
plate with a clean and soft blade cloth and coat
the sealing surface of valve clack with a thin
layer of #400 grinding agent.
Put the circle shape plate on the sealing
surface, and manually push it to distribute the
weight of the plate evenly to the sealing
surface. Grind the plate by moving it at all
direction evenly until defects such as scratches
and crackle are eliminates and a mirror face is
formed.
Note: during grinding, prevent the internal and
external edges from running put of the sealing
surface of valve clack to avoid damage to
sealing surface. In addition, the cone part
should not be crashed.
4. Wipe up the sealing surface of valve clack
with a clean and soft blade cloth, and measure
the project value(C-B) of the sealing surface,
see Fig 3-9. Replace the valve clack if the
measured value is less than tabulated value.
5. Check the end section of valve clack junk
ring and two holes on the valve clack junk ring.
Grind the outer surface with metallographical
sand paper until it becomes glossy.
6. Check the internal surface and ellipticity of
the guidance and check the outer thread of the
guidance.
7. Measure and record the clearance between
guidance and valve clack junk ring.
1. No corrosion, crackle,
or nick is on the valve
clack; sealing surface is
glossy without notch,
stain; the thread is not
damaged.
2. No corrosion on end
section of valve clack junk
ring; steam hole is
free-flowing; no ellipticity
of the outer diameter of
the junk ring; no serious
abrasion on the outer
surface, which is plain
and smooth.
3. No ellipticity of the
inner surface of the
guidance; no serious
abrasion, and no damage
on thread.
4. Requirements on the
clearance between
guidance and valve clack
junk ring are shown in
tables.

SEC
2300 MW

Date: 2008-10-20 No.:QN1-SEC-G-04-TP-009 - 74 -
Rev. : A

Maintenance
item
(IV) Check of
overlapping
lantern ring and
cover plate
1. Check outer surface and thread of lantern
ring.
2. Grind the outer surface of the lantern ring
with crocus paper.
3. Check surface of cover plate and steam
exhaust hole.
4. Check inner surface of levitation gasket and
guard ring of the gasket.
1. No defect or flaw on
the outer diameter of the
lantern ring; surface is
glossy; thread is not
damaged.
2. Cover plate is plain
without any deformation.
3. No seizing, bending or
deformation of levitation
ring is in the cover; its
inner surface is smooth
without any Pitting or
abrasion.
4. No damage or serious
abrasion to the guarding
ring of the gasket.
(V) Maintenance
of the valve seat
sleeve
1. Wipe up the sealing surface of valve seat
with a clean and soft blade cloth, and check the
sealing surface.
2. The grinding of valve seat sleeve is the
same as valve clack. However, before grinding,
grind the taper angles on the edges to
eliminate small metal particles and burrs.
3. Measure the size shown in Fig 3-1; replace
the valve or resurfacing weld the sealing
surface of the valve seat sleeve if the
measured value is over limit.
1. Surface of valve seat
sleeve is glossy without
any crackle or damage.
2. No crackle or scratch
on the sealing surface of
the valve seat sleeve.
3. The thickness of the
sealing surface valve seat
sleeve is shown in tables.
(VI) Check of
valve stem
1. Place and secure the valve stem on a lathe;
put the contact head of a dial test indicator on
the surface of the valve stem, and rotate valve
stem to observe the variation of the dial test
indicator.
Note: protect the valve stem with a soft cushion
when secure it and the securing position
should not on the thread.
2. Wipe up the surface of valve stem thread
1. Bending value of valve
stem should be less than
0.177 mm.
2. No damage or burr is
on the valve stem thread.
SEC
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Date: 2008-10-20 No.:QN1-SEC-G-04-TP-009 - 75 -
Rev. : A

Maintenance
item
with a clean blade cloth and check thread.
(VII) Check and
grinding of spring
and spring
gasket
1. Visually inspect the spring.
2. Wipe up the spring gasket with a clean blade
cloth and check supporting surface.
3. #320 particle grinding agent should be used
for primary grinding of spring bottom gasket
and valve stem grinding and then use #1000
particle grinding agent for accurate grinding
until it is qualified. Wipe up spring bottom
gasket and valve stem with a clean and soft
blade cloth after grinding.
1. No crackle or corrosion
on spring.
2. Spring gasket is plain
without deformation or
crackle.
3. Width of back
supporting strip of the
spring bottom gasket and
valve stem is even and in
the range of 3.2~4.8mm.
(VIII) Recovery 1. Clean debris in valve body.
Note: wrap up valve seat sleeve with cloth
when cleaning to prevent sealing surface from
damage and debris from entering valve inlet
tube seat.
2. Vertically erect valve stem on the soft
cushion with the ball end up.
Apply lubricant on the ball surface and thread
of the valve stem, turn the turndown ratio
choke block and valve clack into valve stem.
Slowly slip the valve clack block on valve stem
and seat it on the valve clack.
Note: do not damage valve clack ring. Then
carefully turn the valve clack onto valve stem
and check swaying of valve clack. If valve
clack can not sway, adjust the height of the
valve clack ring until valve clack can freely
sway. After check valve clack swaying, take off
valve clack and junk ring, secure the ring with
stainless steel pin and then install valve clack
junk ring onto valve stem.
3. Install yoke bar into valve body, and secure it
with nut.
Note: the position yoke bar turned in valve
body should be in accordance with the mark

SEC
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Date: 2008-10-20 No.:QN1-SEC-G-04-TP-009 - 76 -
Rev. : A

Maintenance
item
made during disassembly. Coat the thread
with supramoly.
4. Turn the pin of lower adjusting ring into valve
body, and then turn the lower adjusting ring
into valve seat sleeve making the upper end
surface lower than that of valve seat sleeve.
Place a plate on the top of valve seat sleeve;
turn the lower adjusting ring to contact it.
Taking this as reference, rotate the lower
adjusting ring into original position based on
recorded data during disassembling and
secure it with pin. If the original position needs
to be adjusted, 4.13MPa should be used for
setting pressure drop caused by each notch
decreasing.
Note: adjusting ring should be able to turn
slightly after installation; otherwise, the end of
positioning pin needs to be ground as required.
Coat the adjusting ring and thread of the pin
with supramoly.
5. Turn the pin of upper adjusting ring onto
guidance until the marks overlap, where the
pin of upper adjusting ring is previously
located. Measure their lengths and compare
them with recorded data to ensure the upper
adjusting ring is located on the original position
on guidance. See Fig 3-11.
Note: cost the thread of guidance with
supramoly.
After adjustment, secure pin of upper adjusting
ring with pin immediately.
Note: guidance supporting surface of valve
seat should be coated with supramoly.
SEC
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Date: 2008-10-20 No.:QN1-SEC-G-04-TP-009 - 77 -
Rev. : A

Maintenance
item
6. Put the guidance and upper adjusting
block assembly into valve body; measure
the end surface of valve seat sleeve with
depth indicator, and compare it with the
recorded value. The difference is the
distance that the pin of upper adjusting
ring needs to be lowered. It can be carried
out by adjust the number of notches.
Serial No. of orifice
Ring vertical distance during adjusting each
notches (mm)
3 0.038
4 0.038
5 0.038
R 0.038

After adjustment, secure pin of upper adjusting
ring with pin immediately.
Note: guidance supporting surface of valve
seat should be coated with supramoly.
7. Wipe up the surface of valve clack seat
with a clean and soft blade cloth and carefully
install the valve stem into guidance. Check
internal valve body, install and secure the
cover plate onto the valve body after
verification as per marked made during
disassembling.

SEC
2300 MW

Date: 2008-10-20 No.:QN1-SEC-G-04-TP-009 - 78 -
Rev. : A

Maintenance
item
If the turndown ratio is different from tabulated
value, remove yoke support and cover plate
and take off valve stem assembly and valve
clack block. Install a stainless steel pin on the
turndown ratio choke block and install the block
into guidance. Recheck internal valve body
and recover and secure cover plate with nut. If
the turndown ratio is different from the
tabulated value, take off valve stem, and adjust
the notch of turndown ratio choke block. Each
movement of one notch, it will increase or
decrease 0.0254mm.
5. Slip the overlapping lantern ring onto valve
stem and turn it clockwise until the lowest line
on the lantern ring is at the same level as
levitation gasket. Turn it to the original position
based on recorded notch number and taking
pin hole as reference. Install stainless steel pin
through the notch of overlapping lantern ring.
Note: coat thread of valve stem with supramoly
before install overlapping lantern ring onto
valve stem.
6. Install spring bottom gasket, spring and top
gasket of spring onto valve stem in sequence.
Put the locking nut onto the thrust screw, and
turn the thrust screw into yoke support until
screw end comes out of bottom of yoke
support. Put the yoke support onto valve stem
and yoke bar. Align the locking nut with spring
gasket during installation. Turn the yoke bar
nut into yoke bar and secure it with torque
wrench. Torque for different pressures is
shown in tables.
Note: coat the spring bottom gasket and thread
with supramoly
7. Turn the thrust screw into original position
and tighten the locking nut.
Note: coat thread of yoke bar nut, thrust screw
locking screw with supramoly. Coat top
surface of yoke bar screw with supramoly.
8. Put the reset nut onto valve stem and turn it
clockwise until it is fully engaged with valve

SEC
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Date: 2008-10-20 No.:QN1-SEC-G-04-TP-009 - 79 -
Rev. : A

Maintenance
item
(IX) Hydraulic
pressure setting
of safety valve
1. Remove cap and lever assemble of safety
valve, loose locking nut and install setting
device for primary setting.
2. Stabilize steam pressure at 70%~80% of
working pressure as setting pressure.
Note: the fluctuation of setting pressure shall
be less than 1%, the indication of local steam
pressure prevails.
3. Startup hydraulic pressure pump, increase
the pressure until Chichi sound comes from
safety valve; record the pressure reading.
Calculate the setting pressure of safety valve
according to the data in table. (Refer to
Table3-1 and Table 3-2).
4. Adjust bolt as per pressure data of the
primary action and record the adjustment. To
increase jumping pressure, turn the thrust bolt
clockwise.

(X) Site thermal calibration (determine calibration quantity as
required)
1. Special personnel should be appointed for instructing calibration
of safety valve.
2. When boiler pressure reaches 80% of working pressure, block
safety valves not required for setting, and recover them after
calibration.
3. If safety valve does not act when the pressure exceeds setting
value of safety valve 0.5MPa, relief the pressure to below 80% of
opening value and adjust thrust screw.
Note: turning clockwise will increase opening value, and turning
counterclockwise will decrease the opening value .Tighten locking
nut after each adjustment.
4. Perform calibration of safety valve after adjust the adjusting
screw properly.
5. After calibration of safety valve, record the jumping up time and
reseating pressure.
1. Safety valve pops
normally.
2. Difference between
popping pressure and the
setting value is lower than
1%.
3. No leakage occurs
after safety valve
reseating.
SEC
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Date: 2008-10-20 No.:QN1-SEC-G-04-TP-009 - 80 -
Rev. : A

3.2 Maintenance of Solenoid Relief Valve
3.2.1 Maintenance of Solenoid Relief Valve
(I) Maintenance
preparation
1. Close the isolating valve below
master valve and turn off the power of
controller.
2. Push operating lever down to
bottom to relieve the remaining
pressure in pilot valve and master
valve.

(II) Master valve
disassembly
1. Remove flange bolt and nut of
steam discharge pipe and take off
steam discharge pipe. Remove flange
nut of valve seat and take off lantern
ring (outlet flange). Slightly click and
loose C sealing ring on the contacting
surface of valve seat flange, and take
it off.
Note: do not damage the sealing
surface during removal C sealing
ring ; bolt and should be put into oil by
pairs after removal.
2. Knock and loose the valve clack
and guidance with copper bar. Turn a
screw stem into the hole on the top of
valve clack to take out valve clack
and then take out spring in guidance.
Note: do not crash the valve clack
and guidance with valve seat or valve
seat thread when taking them out.
3. Knock and loose the retaining ring
with copper bar, and take it out.

(III) Check and
grinding of master
valve parts

1. Wipe up the sealing surface S with
clean blade cloth and diesel before
check the sealing surface of master
valve seat check.
2. When primarily check the sealing
surface, perform grinding if any
1. Sealing surface of valve
seat is glossy and plain without
damage or corrosive pitting or
dent.
2. No dirt in valve seat or thread.
SEC
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Date: 2008-10-20 No.:QN1-SEC-G-04-TP-009 - 81 -
Rev. : A

obvious defect or corrosive pitting is
found. Firstly coat coarse particle
grinding agent on plate to grind
sealing surface until defects are
eliminated, and then apply fine
particle grinding agent for accurate
grinding until sealing surface is
glossy. At last, apply polishing
grinding agent on plate to polish the
sealing surface. See Fig 3-14.
Note:(1) before grinding, use crocus
paper to round chamfer of grinding
surface and other valve seat surfaces
to remove metal particles on sharp
angles. (2) After every grinding, wipe
up sealing surface with clean blade
cloth. (3) Grinding should be evenly
performed with the same direction.
3. If no defect is found on the sealing
surface at the primary check, coat
medium particle grinding agent on a
special plate and grind the sealing
surface until small pots are
eliminated. Then wipe up it with clean
blade cloth and recheck sealing
surface. If any crackle or corrosive
pitting is found, perform grinding as
per procedure 2.
4. Clean the inner wall and thread
of the valve seat with diesel and blade
cloth.
5. Put sleeve, guidance, valve clack,
and spring and check washer into oil
to wash them, and wipe up them with
clean blade cloth.
6. Check and grind the bottoms of
sleeve sealing surface C and C
sealing ring. See Fig3-15 and Fig
3-16. The method of check and
grinding is the same as Procedure 2.
3. No dirt inside or outside of
sleeve; thread is intact without
burrs; sealing surface is glossy
and plain without damage or
corrosive pitting; no crackle on
sealing surface of valve clack
seat.
4. Sealing surface of valve clack
is glossy and plain without
damage or corrosion; well
contact with valve seat with
continuous and even contacting
surface.
5. Surface of lock washer is
glossy and plain without dirt and
spring is not loose.
SEC
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Date: 2008-10-20 No.:QN1-SEC-G-04-TP-009 - 82 -
Rev. : A

If the depth of the notch exceeds
6mm, grind sealing surface to recover
it to the original value.
7. Check sealing surface of sleeve
and valve clack. The method is the
same as that of procedure 2 and 3. If
the sealing surface is found seriously
damaged during the primary check,
machining is needed to recover it to
original size.
Note: sealing surface is required to be
ground after machining. The method
is the same as procedure 2. During
grinding, the centerline of plate
should be in accordance with those of
sleeve and guidance.
8. Wipe and check the sealing
surface of valve clack. If any crackle
or corrosive pitting is found on the
sealing surface, continue to process
valve clack. After machining, grind the
valve clack to fit sleeve. Put valve
clack on sleeve with matching their
centerline. Mark a connecting line on
the sleeve, which is the upper edge of
connecting surface between valve
clack and sleeve. Carefully coat a
little grinding agent below the
connecting line, and place valve clack
seat of sleeve again. Perform grinding
after alignment until the width of
contacting surface is 1/3 of the valve
clack seat of sleeve. See Fig 3-17.
The area in the sealing surface of
valve clack and sleeve. Coat grinding
agent to grind the sealing surface.
9. Check the surface of guidance,
spring, check washer, and check the
relaxation of spring.
SEC
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Date: 2008-10-20 No.:QN1-SEC-G-04-TP-009 - 83 -
Rev. : A

(IV) Assembling of
master valve
1. Put the spring and check washer
on valve seat.
2. Put the guidance into valve seat
and securely seat on the supporting
plate.
3. Connect the valve clack with
installation screw stem, and carefully
put valve clack into the guidance by
aligning with the spring.
4. Coat the thread of sleeve with
supramoly, and fill Vaseline into the C
sealing groove. Put the C sealing ring
into it and turn it into master valve
until the sealing ring contact with
valve seat.
5. Coat the screw with supramoly,
turn it into the valve seat and tighten
it. Recover the lantern ring (outlet
flange) and tighten it with nuts.
1. Guidance is well located and
connected with supporting
plated without swaying.
2. Spring is well located without
swaying or inclination.
3. Valve clack spring is well
contacted.
4. Sleeve is well contacted with
valve seat, and C sealing ring is
well located.
(V) Pilot valve
disassembling
1. Remove stud bolt of the frame
gland and take off frame gland. And
remove frame together with solenoid
coil assembly from the controller.
2. When removing parts in pilot valve,
stick valve clack to valve seat, and
press it with spring cap. Then remove
the pin of spring cap and spring.
3. Take out pilot valve stem and pilot
valve clack from the pilot valve seat.
Note: do not crash valve seat.
4. Slightly kick valve clack with small
hammer to pull valve stem out of pilot
valve clack.
Note: valve stem and valve clack
should be carefully laid.

SEC
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Date: 2008-10-20 No.:QN1-SEC-G-04-TP-009 - 84 -
Rev. : A

(VI) Check and
grinding of pilot
valve parts
1. Clean valve seat cover with a clean
blade cloth and diesel, grinding
method of pilot valve seat is the same
as that of master valve sleeve. See
Fig 3-18 and 3-19.
2. Put pilot valve clack, valve stem
spring cap and pin of spring cap into
oil for washing and wipe them with a
clean blade cloth.
3. Put the valve clack on a special
grinding tool to grind the sealing
surface. If any defect such as
abrasion, crackle or corrosion is
found on the sealing surface,
machining is needed. Grind it after
machining. Building-in of valve clack
and pilot valve seat cover is the same
as that of master valve clack and
valve seat.
4. Check the surface and bending
ratio of pilot valve stem.
1. No dirt is in the pilot valve
seat and the sealing surface in
pilot valve seat sleeve is plain
and glossy without crackle or
corrosion.
2. Pilot valve clack is plain and
glossy without crackle, abrasion
or corrosion. It is well
contacted with sealing surface
of pilot valve seat sleeve.
Contacting surface is
continuous and width is uniform.
3. Surface of pilot valve stem is
glossy and flat with a bending
value <0.10 mm.
4. Spring of pilot valve stem is
not relaxed.
SEC
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Date: 2008-10-20 No.:QN1-SEC-G-04-TP-009 - 85 -
Rev. : A

(VII) Assembling of
pilot valve

1. Wipe valve stem and insert it into
valve clack. And then insert the well
connected assembly into pilot valve
seat sleeve. Then put spring and
spring cap onto pilot valve stem.
Install pin of spring cap after tightly
press spring.
2. Clean pilot valve seat and valve
seat sleeve with a clean blade cloth.
Replace packing seal ring on valve
seat sleeve, and then carefully put
sleeve into valve seat.
Note: do not crash valve stem valve
clack assembly with valve seat sleeve
during assembling.
3. Install solenoid coil support and
tighten it with nut, tightening of nut
should be carried out by diagonal
sequence. Turn 1/4 circle every time
until support fully contact with valve
body.
Note: before turn in bolt and nut, coat
thread with supramoly.
1. No relaxation of the
connection between valve stem
and valve clack.
2. Sleeve is well secured in
valve seat.
3. Solenoid coil support well
contacts with valve body, and
clamp nuts of support is evenly
tightened.
3.3 Maintenance of water level gauge
Item Workmanship and precautions Quality standard
(I) Check
preparation
1. After receipt of maintenance permit, check
the air valve and local pressure gauge to make
sure the pressure inside drum is equal to
ambient pressure.
2. Open the drain valve water level gauge to
drain the water in water level gauge and
piping.
3. Cut off lighting power supply of water level
gauge and remove cover.

SEC
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Date: 2008-10-20 No.:QN1-SEC-G-04-TP-009 - 86 -
Rev. : A

(II)
Disassembly of
water level
gauge
1. Loose the gland nut of the water level
gauge with wrench and take it out. Knock the
gland bush with the wooden hand handle of
hammer or other tools to loose it and take it off.
2. Orderly take out packing seal, mica
lamination, protective pad, plain glass and
buffer cushion in gland bush.
3. Coat the connecting bolt of gland bush and
water level gauge with rust loosing agent and
turn the bolt out with wrench.
Note: bolt and should be put into oil by pairs
after removal.

(III) Check and
clean of water
level gauge
parts

1. Clean the gland bush and sealing surface
with blade cloth and diesel, remove relict of
graphite adhering to sealing surface. Clean the
sealing surface with blade cloth and check
sealing surface. If any defect such as corrosive
pitting, groove or abrasion is found on sealing
surface, grind the sealing surface with special
plate and abrasive paper. Machining is needed
for serious defects.
2. Put the gland bush on a platform or plate
and measure the bending ratio of gland bush.
Note: sealing surface of gland bush should be
towards to platform or plate during
measurement.
3. Remove dirt on bolt and nut. Check bending
ratio of every bolt. Try turning nut to check the
thread of bolt and nut.
Note: nut should be turned through entire bolt
thread. They should be stored by pair
4. Check mica lamination and plain glass.
1. The sealing surface
between the body of water
level gauge and gland bush
is flat without corrosive
pitting, groove, or abrasion.
The surface coarseness of
the sealing surface after
grinding should reach
Ra1.60m.
2. Bending value of gland
bush is less than 0.15mm.
3. Bending value of the bolt
is less than l mm. No
defect on or damage to the
thread of bolt and nut.
4. Mica lamination is flat
and transparent with
uniform thickness and
without stain or crease.
5. The plain glass is
transparent without notch
and with uniform thickness.
SEC
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Date: 2008-10-20 No.:QN1-SEC-G-04-TP-009 - 87 -
Rev. : A

(IV)
Assembling of
water level
gauge

1. Purge communicating pipe of water side
and steam side of water level gauge with
compressed air, and remove dirt inside pipes.
2. Turn bolt into the body of water level gauge.
Note: the end with short thread of the bolt
should be turned into the body of water level
gauge with supramoly coated on the thread.
3. Orderly install the cushion gasket of plain
glass, protective cover of the upper and lower
ends of plain glass, plain glass, mica
lamination and high strength graphite packing
seal into the gland bush of the water level
gauge. Then connect the gland bush and
water level gauge with nuts as per the
sequence shown in Fig 3-21.
Note: (1) clean the sealing surface before
assemble the body of water level gauge and
the gland bush. Washers should be used for
nut connection. (2) tighten nuts respectively
four times with torques as 90Nm,120Nm,
150Nm and 180Nm.
1. The communicating pipe
of water side and steam
side of water level gauge is
smooth and clean.
2. High strength graphite
packing seal is plain without
impress or crease, and the
width and thickness are
uniform.
3. Tightening torque on
gland nuts is uniform.
(V)
Disassembling
of stop valves
on steam side
and water side

1. Fully open the valve and remove gland nut
of handwheel to remove the handwheel.
2. Loose the gland nut of the gland bush of
gland box to separate the gland nut from gland
bush. Knock the gland bush until it is loose and
pushed out of the gland box.
3. Loose and take off the stud bolt of valve
cap, and knock the valve support downwards
to take out the collar of valve cap.
4. Turn the valve stem towards closing
direction with wrench until the valve stem
together with valve disc separate from the
valve body.
5. Coat rust loosing agent on the connecting
surface between valve cap and valve body.
Knock the valve cap with copper bar to make it

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Date: 2008-10-20 No.:QN1-SEC-G-04-TP-009 - 88 -
Rev. : A

turn counterclockwise until it separate from
valve body. Secure the valve cap and coat rust
loosing agent on the contacting surface of
valve cap and valve cap nut. Then loose the
valve cap and turn it out.
(VI) Check and
cleaning of
valve parts

1.Wash the inside of valve body, surface of
gland box and sealing surface of valve seat
with a blade cloth and diesel, and check inside
of valve body and the sealing surface of the
valve seat.
2. Clean the inner and outer thread of the
valve cap with a blade cloth and diesel and
check the threads.
3. Clean the valve disc with blade cloth and
check its sealing surface. Any stain or crackle
should be eliminated by lathe.
4. Grind the sealing surface of valve seat with
special grinding tools. There are three grinding
levels: coarseness, fineness and precision.
#0--2 abrasive paper is used for coarseness
grinding, #0-00 abrasive paper is used for
fineness grinding and #000 abrasive paper
with oil on surface is used for precision
grinding.
5. Grind the surface of valve stem with crocus
paper coated with oil. Clean with blade cloth
and check the thread and the arch part of
valve stem. Put the valve stem on a lathe and
check the bending ratio of valve stem.
1. No corrosion on the
internal wall of the valve
body and the surface of
gland box is glossy and
plain without corrosion.
2. No corrosive pitting or
scratching on sealing
surface of the valve seat.
3. Inner and outer threads
of the valve body and valve
cap are free of burrs or
deficiency.
4. On burr or abrasion on
the valve stem thread with
a bending value less than
0.15mm. The top arch of
the valve stem is intact
without abrasion.
5. No crackle of notch on
the sealing surface of the
valve disc.
(VII)
Assembling of
valves
1. Grind the sealing surface of the valve seat
by special grinding tool with #200 grinding
sand coated on the grinding head. Then coat
the sealing surface of the valve disc with red
lead powder and assemble valve disc and
valve seat.
2. Put the valve disc and valve stem into valve
body after assembling.
1. The sealing surface
between valve seat and
valve disc is continuous
and the width of sealing
surface is evenly around
2mm.
2. The clearance between
top of valve stem and valve
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3. Put the gland bush of the gland box on the
valve stem and fill gland packing into gland
box.
Note: the opening of packing should be
stagger with 90.
4. Turn the valve cap into valve body until
secure the valve cap with stud bolts. Install
collar into valve cap. Insert gland bush bolt into
gland bush and tighten it with nut.
Note: the thread of valve body and gland
bush bolt should be coated with supramoly.
5. Turn valve stem nut into valve cap and
tighten it.
Note: nut thread should be coated with
supramoly.
6. Recover valve handwheel and tighten it with
nut.
7. Rotate the handwheel to make valve stem
operate freely.
disc is 0.3~1mm.
3. The operation of opening
and closing valve is freely
without seizing.
(VIII) Zero
calibration and
check of water
level gauge
1. Find out the horizontal center points from
the circumferential direction of the two sides of
drum cylinder.
2. Connect the horizontal center points of the
two sides with the water level gauge by a hose
filled with water.
3. Taking the position of horizontal center point
as reference, the zero level of the drum water
level gauge is 328.6mm below.
4. Taking the position of horizontal center point
as reference, measure the inclined value and
inclining direction of drum. Based on the
inclining direction, calculated out the position
line of zero level and mark it.

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3.4 Maintenance of Desuperheating Control Valve
Maintenance
item
(I)Disassembly 1. Remove signal feeding back mechanism on the
actuator and the connecting block of valve stem and
valve actuator.
2. Slightly knock the retaining nut of actuator and
valve yoke support with hammer and flat chisel until
the nut is fully loose and take it off.
3. Lift the actuator away from valve and well store it.
Take out indicating dial of turndown ratio on the valve
stem and its retaining nut.
4. Remove gland cover nut and take out junk ring of
gland cover and packing.
5. Counterclockwise knock the flange nut of the valve
cap with hammer and wrench until it becomes loose.
Remove valve cap from valve body.
Note: do not crash the valve stem when separating
valve cap.
6. Take out valve stem, valve disc assembly and
valve seat sleeve. Then loose the junk ring of the
valve seat by wrench. Take out junk ring of valve seat
and valve seat ring.

(II) Cleaning
valve parts

1. Clean gland box of valve cap with diesel and blade
cloth. Then grind the internal wall to smooth.
2. Clean valve seat ring and junk ring of valve seat
with diesel and blade cloth. Then grind the sealing
surface of valve seat and valve seat ring.
3. Clean the surface of valve disc with blade cloth
and check its sealing surface. Assemble the valve
disc and valve clack.
4. Grind the surface of valve seat sleeve with crocus
paper, and check and measure its ellipticity.
5. Clean the valve stem with diesel, and check its
thread and bending ratio.
6. Clean the internal valve body with blade cloth and
1. Internal wall of
the gland box is
Glossy without
notch, corrosion, or
air hole.
2. The sealing
surface between
valve seat and
valve seat ring is
plain without
abrasion, crackle,
or corrosive pitting.
3. The internal and
external surface of
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Rev. : A

check its internal wall and grind the flange of valve
body with crocus paper.
7. Clean the thread of valve cap yoke support with
diesel and blade cloth and check its thread. Grind the
flange surface of valve cap yoke support with
abrasive paper.

valve disc is clean
and glossy without
deformation,
abrasion, crackle or
corrosive pitting.
4. Surface of the
valve seat sleeve is
glossy without
abrasion, crackle,
With an ellipticity
less than 0.10mm.
5. Valve stem
thread is not
damaged with a
bending value less
than 0.15 mm.
6. No dirt or debris
inside valve body;
internal wall of
valve body is free
of corrosion, air
hole or crackle.
7. The contacting of
valve seat ring and
valve disc is
continuous with an
even width.
8. Flange is ground
with metal luster.
(III) Assembling

1. Carefully put the gasket of the valve seat ring into
valve seat, and tighten the valve seat junk ring with
special tool.
Note: thread of the valve seat junk ring should be
coated with supramoly.
2. Put the valve seat sleeve into valve body. Put
packing on the valve stem and assemble it with valve
disc, then put them into valve seat sleeve to contact
with valve seat ring. Rotate the valve stem to ensure
1. Valve disc
rotates freely
without seizing.
Clearance between
valve disc and
sleeve is 0.10- 0.20
mm.
2. Clearance
between gland
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valve disc can operate freely.
3. Put gasket on the valve body flange; recover valve
cap and tighten the nuts.
Note: surface of HP gasket and connecting bolt
should be coated with supramoly.
4. Install packing assembly into gland box; tighten the
packing with junk ring and gland bush, and then
tighten bolts.
5. Turn the retaining nut and turndown ratio indicating
dial of the actuator into valve stem, and lift actuator to
the yoke support of valve cap. Symmetrically put two
shim plates with a thickness of 35mm on the yoke
support. Adjust thread of valve stem, and recover the
connecting block of actuator and valve; secure the
turndown ratio indicating dial.
6. Take out two shim plates and recover yoke support
nuts.
cover and valve
stem is uniform.
3. Threads of valve
stem and valve
stem sleeve are
well engaged with
that of connecting
block.
3.5 Valves
3.5.1 Maintenance of HP Gate Valve
HP gate valve is used to cut off or put through boiler feed water or desuperheating water. It
is a kind of self-sealing gate valve. Main feed water gate valve is double ram type while the feed
water bypass gate valve and desuperheating water gate valve are single ram type. The
connection and disconnection of flow is achieved by movement of wedge valve clack and
sealing of wedge valve seat.
Maintenance
item
(I)Disassembling 1. Remove external connecting wires of actuator and
remove connecting bolt of valve and actuator; lift the
actuator away from valve and carefully store it.
2. Remove the retaining bolt on the top frame of
valve cap; turn the valve stem nut counterclockwise
to take off valve frame from valve body. Lift the fame
and put it at suitable position. Valve stem is ready for
disassembling check.
3. Remove gland cover nut and take out gland cover
and packing junk ring.

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4. Take out retaining ring at the sealing ring of valve
body; press down valve cap with special tool. Knock
the valve cap with valve cap hammer to make a
clearance between it and six-element ring; take out
six-element ring and lift valve cap, valve stem, valve
clack out of valve body .
5. Take out upper and lower cleat disassembly of
valve clack frame, left and right valve clack. And take
care of the universal jack and gasket. Measure and
record the total thickness of the gasket.
6. Cover the valve body with special cover plate and
stick seal on it.
(II) Cleaning
valve parts

1 remove valve cap and self- sealing gland packing;
remove scaling and rust on the external wall of the
packing retaining ring; grind it with abrasive paper to
be glossy.
2. Clean the packing set of valve stem gland box and
verfy that internal packing seat retainer is intact,
clearance between internal hole and valve stem
meets requirements and no seizing exists between
outer ring and internal wall of gland box.
3. Grind the sealing surface of valve seat and valve
clack.
4. Coat the sealing surface with red lead powder;
assemble the valve seat and valve clack. Check the
engagement of sealing surface between valve clack
and valve disc after grinding.
5. Grind the surfaces of gland cover and six-element
ring with abrasive paper to remove rust.
6. Clean the valve stem with diesel and check its
thread and bending ratio.
7. Clean the internal valve body with blade cloth and
then check its internal wall.
8. The flange surface of valve cap frame should be
ground by abrasive paper.
9. Wash the valve stem nut and internal bearing with
diesel.
1. Internal wall of
gland box is glossy
without notch,
corrosion, or air
hole.
2. Roughness Ra
value of the sealing
surface between
valve seat and
valve clack after
grinding is 0.4
without abrasion,
crackle, or
corrosive pitting.
The engaging
surface between
valve seat and
valve clack should
have a width of 2/3
of total.
3. Welding of valve
seat is free of
abrasion, crackle,
4. Valve stem
thread is not
damaged with a
bending value less
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Rev. : A

than 0.10 mm.
inside valve body;
internal wall of
valve body is free
of corrosion, air
hole or crackle.
7. Bearing turns
freely without
seizing.
(III) Assembling

1. Reinstall valve clack to retaining ring of valve stem,
and secure it by the upper and lower cleats. Then put
in universal jack or spring. Adjust the gasket number
depending on the volume ground from valve clack
seat.
2. Clean inside of valve body, and put valve stem
together with valve clack into the valve body. Check
the relative height of valve clack sealing surface to
that of valve seat. Adjust the gasket if necessary.
3. Install gland packing at the self-sealing parts of
valve cap as required. Press upper packing with
retaining ring. Then install six-element ring and seal it
with cover plate. Tighten the nut for lifting bolt of
valve cap.
Note: connecting bolts should be coated with
supramoly.
4. Put the valve stem packing assembly into gland
box; tighten the packing with junk ring and gland
bush, and then tighten bolts.
5. Recover the frame of valve cap, and turn the upper
valve stem nut to set the frame on the valve body.
Tighten it with connecting bolts.
6. Lift actuator to the frame of valve cap; manually
operate the actuator until it engages with the valve
stem nut. Tighten the connecting bolts and manually
check the closing and opening operation.

1. Sealing surface
of the valve clack
should be 3-5 mm
higher than seat
sealing surface.
2. Clearance
between gland
cover and valve
stem is uniform.
3. Threads of valve
stem and valve
stem nut are well
engaged.
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3.5.2 Maintenance of HP Stop Valve
HP stop valve is used to cut off or put through the working medium in pipes. The body of
stop valves used for boiler drainage system and exhaust system, stop valve are streamline type
normally to reduce flowing resistance loss. The sealing methods of valve cap include flange
type and self-sealing type while the sealing surface is divided into plain type and cone type.
Maintenance
item
(I)disassembly 1. Remove set screw and grind the welding points
from the conjunction part of valve cap and valve
body by an angle direction grinding wheel.
2. Close valve and take out retaining ring.
3. Manually rotate the frame counterclockwise, and
take out the valve cap, valve stem, and assembly
around frame from valve body.
4. When disassembling valve stem, remove
handwheel first and rotate the valve stem clockwise
and pull it put at the same time.
5. Clean internal valve body and check sealing
surface of valve seat; cover the valve body with
special cover.

(II) Cleaning of
valve parts

1. Clean valve cap and gland box packing, and
remove gland cover, retaining ring and packing seat
retainer. Then grind them to be glossy to ensure
gland bush can be freely installed into the gland box.
2. Put the sealing surface of valve clack on lathe for
polishing, and grind the sealing surface of valve seat
with grinding tool.
3. Grind the sealing surface valve seat and valve
clack.
4. Wipe the sealing surface with red lead powder,
and face up the sealing surface of valve seat and
valve clack. Check the engagement of valve clack
and valve disc.
5. Clean valve stem with diesel and check its thread
and bending ratio.
6. Clean internal valve body with blade cloth and
1. Internal wall of
the gland box is
glossy free of notch,
corrosion or air
hole.
2. Roughness Ra
value of the sealing
surface between
valve seat and
valve clack after
grinding is 0.8
without abrasion,
crackle or corrosive
pitting. Valve seat
and valve clack
should have a width
of 2/3 of total.
3. Clearance
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checkits internal wall.
7. Check valve stem nut and bearing.
between internal
bore of packing seat
retainer and valve
stem is 0.25-0.35
mm; no seizing
exists between the
outer bore and
internal wall of
gland box.
4. Thread of valve
stem is not
damaged with a
bending valueless
than 0.10 mm.
inside valve body;
internal wall of valve
body is free of
corrosion, air hole
or crackle.
(III)Assembling

1. Check no foreign matter in valve body and clean
internal valve body.
2. Install valve clack, valve stem, valve cap into
valve body.
3. Install valve stem packing into gland box and
press packing with gland bush.
4. Install retaining ring and tighten valve cap ring,
gland cover bolt.
5. Install handwheel and set valve in close state.
6. Put on the nameplate of valve and clean the site.
1. Clearance
between gland
covered valve stem
is uniform.
2. Thread of the
valve stem and
valve stem nut are
well engaged.
3.6 Blowdown Flash Tank
3.6.1 Technical Specifications of Blowdown Flash Tank
The tank is composed of steam-water separator, throttle ring, and steam-water separating
baffle with a horizontal arrangement.
Manufacturer: Jinan Pressure Vessel Factory
Main technical parameters of blowdown flash tank:
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Name Regular blowdown flash
tank
Continuous blowdown flash
tank
Design pressure (MPa) 0.98 1.040
Design temperature( ) 300 364
Working pressure (MPa) 0.0098-0.392 0.912
Working temperature ( ) 102-151 181
Working volume (m
3
) 12 Steam 2.2 / water 0. 8
total volume (m
3
) 14.8 3
Max. blowdown rate (t/h) 20.6(2% of the rated
evaporation)
Normal blowdown rate (t/h) 10.3(1% of the rated
evaporation)
Internal diameter of cylinder
(mm)
2000 1200
3.6.2 Maintenance of Blowdown Flash Tank
Taking the maintenance of regular blowdown flash tank as example, the maintenance of
continuous blowdown flash tank shall be in accordance with:
1) During outage, anti-corrosion provisions should be carried out.
2) Outside of equipment should be checked every year while the inside should be checked
every three years. The content check include: check and treatment of appearance, the
corrosion and abrasion of parts inside and outside of equipment, thickness of pressure parts.
3) If the maintenance and check may affect the security of equipment, pressure
withstanding test should be carried out. Pressure withstanding test on equipment should be
performed at least every ten years. (As per the test pressure specified on the name plate)
(I) Check
preparation
1. Open the exhaust steam valve and draw-off
valve to ensure the pressure inside vessel is equal
to the ambient pressure without residual water.
2. Open the manhole to fully cool the vessel with a
natural method.
Note: maintenance staff should not enter the
vessel until the temperature drops below 40 .
Set a temporary manhole with suitable

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Rev. : A

maintenance clearance. The lighting and electric
tools used in vessel should be in accordance with
Clause 272 and 274 specified in [Working
Regulation of Power Safety] (part of heating power
and the machine section).
(II) Check vessel
internal wall and
parts
1. Check the scaling of internal wall by chemical
supervision staff and take sample of scale.
2. Clean the internal wall and the surface of
steam-water separating baffle with compressed air
and steel wire.
3. Check the circular seam and longitudinal seam
on the internal wall of vessel. Repair the welding if
scallop or crackle is oversize.
4. Check the weld seams between steam-water
separating baffle and cylinder and those among
themselves.
5. If steam-water separating baffle falls down
because of impulse, check the throttle ring and
steam-water separator. Replace the seriously
deformed steam-water separating baffle or throttle
ring.
6. Grind the fillet weld on the tube support with
grinder and then check the crackle on the fillet
weld by means of staining method.
1 internal wall of
cylinder, surface of
steam-water separating
baffle is plain without
dirt. Steam-water
separating baffle is well
welded with the cylinder
without crackle or
sealingoff.
2. The size of scallops
on the internal wall of
cylinder should be less
than 5mm.
3. The throttle ring and
steam-water separator
are free of deformation
or falling down.
4. Weld seam of tube
support on the cylinder
is free of crackle.
(III) Close the
manhole
1. Clean the residual matters on the manhole
contacting surface with perching knife. And then
grind it with abrasive paper. If serious notch or
abrasion is found, repair the weld of defects and
grind the surface to be glossy.
2. Clean and check the inside of the cylinder
before close the manhole.
Note: coat supramoly on the both sides of the
HP sealing packing gasket and bolts.
3. Close the manhole and tighten it with nuts. Nuts
should be tightened as per diagonal sequence.
Retighten them in hot state.
1. No any matter is left
inside the vessel.
2. The contacting
surface of the manhole
is plain, and glossy
without notch or
abrasion.
3. The contacting
surface is well touched
after manhole closing
and the bolts are evenly
forced.
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4. Contacing surface of
manhole is free of
leakage.

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4 Coal pulverizing system
4.1 Steel Ball Coal Mill
4.1.1 Steel Ball Coal Mill Technical Specifications
BBI4796 type steel ball coal mill is manufactured by Shanghai Heavy Machinery Plant
Company Limited. It is equipped with jacking oil system and slow speed drive device. It is
composed of front and rear hoppers, rotating part, main bearing, drive component, reducer,
gear and pinion, lube oil system and motor. Rotating part is a cylinder made by steel plate and
its inner wall is furnished with wave-shaped steel tiles. The material is hard low alloy liner plate.
There is a layer of asbestos rubber pad between cylinder and liner plate, which is used to
prevent heat inside cylinder from losing and to buffer the impulsion from steel balls. Hard
wearing steel ball are equipped inside of cylinder. The rotating speed of cylinder is 13.18 r/min.
There is an end cap for each end of cylinder. Inner cap is furnished with sector liner plate and
asbestos rubber pad. Outer cap is connected with hollow shaft. The neck of hollow shaft is
located on the bearing of main shaft. Each end of hollow shaft is connected with a 45 degree
elbow. One is for inlet of raw coal and drying medium and the other is used as outlet of
air-pulverized coal mixture.
When cylinder rotates, steel balls are taken to a certain height by the wave-shaped steel tiles
and fall down to strike raw coal. Raw coal is ground to pulverized coal under the combine action
of steel balls, steel tiles. Drying medium is used to dry and carry pulverized coal. Under the
negative pressure suction of pulverization system, finished pulverized coal is transported along
with drying medium to furnace for combustion.
(II) structure is shown in the figure below:

Diagram of BBI4796 type coal mill
1.Inlet hopper 2. Main bearing 3. Driving part 4. Rotational part 5. Outlet hopper
6. Gear coupling 7. Reducer 8. Flexible coupling 9. Main motor 10. Slow drive device
6 7 8 9 10
1 2 3 4 5
BBI4796
1. 2. 3. 4. 5. 6. 7.
8. 9. 10
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4.1.2 Main Technical Performance
4.1.2.1 Coal Pulverizer Type: BBI4796
Coal pulverizer cylinder effective inside diameter: 4650 mm
Coal pulverizer cylinder effective length: 9740 mm
Application: for boiler coal pulverizing system of coal-fired power generation unit
Pulverization method: steel balls impact and grinding together with hot air blowing and
drying
Input particle size: 25 mm
Coal pulverizer name plate output: 100 t/h
Cylinder rotate speed: 13.18 r/min
Max. Load of steel balls: 256 t
Cylinder effective volume: 165.3 m3
Feed port size: 11401300 mm
Size of outlet hopper air ventilation port: 1069 1740 mm
Size of outlet hopper powder discharge port: 1288 1740 mm
Exposed gear: Module:28; large gear Tooth number :250; small gear Tooth number :31
4.1.2.2 Main motor:
Type: YTM900-6
Power: 3500 kw
Voltage: 6600 V
Rotate speed: 986 r/min
Efficiency: 50HZ
Electric heater voltage, single phase,230V, power 12002 W (used for shutdown)
Main motor lubrication oil dilution station (XYZ-20):
Nominal pressure: 0.5 mpa; nominal flow:20 L/min
Original lube oil: 450 L
Lube oil brand: 46 steam-turbine oil L-TSA
Cooling water consumption: 2.5 m3/h
Power: 1.5 kw ; voltage: 400 V; rotate speed:1400 r/min
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4.1.2.3 Main reducer:
Type: ML2PSF150
Speed ratio: I = 9.275
Lubrication method: reducer with independent oil dilution station for forced lubrication
Power: 11 kw
Voltage: 400 V
Lube oil brand: ISO VG320
Cooling water consumption: 8 m
3
/h
4.1.2.4 Slow drive device:
Planetary reducer (with brake motor):
Type: NMCD560-125
Speed ratio :i125
Motor type: YEJ280S-6(B35)
Motor power: 45 kw
Motor rotate speed: 970 r/min
Motor voltage: 400 V
Pan Mill rotate speed: 0.105r/min
Lube oil brand: intermediate extreme pressure industrial gear oil N220(GB5903-86)
4.1.2.5 Main bearing HP/LP lubrication oil dilution station:
4.1.2.5.1 Type: GDR-60/10/170
Lube oil brand: SO VG460
Cooling water consumption: 18 m
3
/h
Electric heater: totally 6(400VAC/3kw 6)
4.1.2.5.2 LP oil pumps (1 set):
Nominal flow: 170 L/min
Nominal pressure: 1 mpa
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LP oil pump motor (1 set):
Power: 7.5Kw; voltage: 400 V; rotate speed:1440 r/min
4.1.2.5.3 HP lifting oil pump(1 set):
Nominal flow:4X15 L/min
Nominal pressure:20mpa
HP lifting oil pump motor(1set):
Power:30 kw; voltage:400 V; rotate speed:1470 r/min
Electric strip heater:230VAC/kw
4.1.2.5.4 HP lube oil pump (1 set):
Nominal flow:25 L/min
Nominal pressure: 10mpa
HP lube oil pump motor (1set)
Power:3 kW; voltage:400 V; rotate speed:1440 r/min
4.1.2.6Exposed gear oil jet lubrication device:
Type: GSPZ-Z-8
Working air pressure: 0.4~0.6 mpa
Max. Air pressure: 0.8 Mpa
Max. Oil delivery: 1500 g/min( air pressure 0.6mpa)
Air supply capacity: 0.42 m
3
/min
Working oil pressure: 20 mpa
Nozzle number: 8
Tooth width 850 mm
Lube oil brand: NLG100-0
4.1.2.7 Large gear sealing air unit
Fan type: CQ3-J
Flow: 800 m
3
/h
Pressure: 590 pa
Motor power:0.37 kw
Motor voltage: 400 V
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Rev. : A

Motor rotate speed:2900 r/min
4.1.3 Steel ball coal mill maintenance
4.1.3.1 Reducer maintenance
Maintenance
item
Maintenance of
reducer casing
1. Disassemble and clean parts; check joint
surface and oil system.
2. Check bearing, gear and teeth engagement
as per common standard for rotating machine.
3. Carry out hydrotest for cooling water pipe.
4. Replace qualified lube oil.
1. The contact between
reducer cover and flange
should be airtight oil system
should be securely installed
without oil leakage.
2. Manually turn the
reassembled reducer; the
shaft should rotate freely
with stable engagement.
3. Test pressure should be
7-8Kg/ cm2.
Maintenance of
oil system:
(I) check and
cleaning of oil
system
1. After assembling oil system, completely clean
and blow the accessories (oil tank, oil pipeline,
oil filter and oil cooler, etc.)To remove debris,
dirt or paint soluble to lube oil before close the
system; do not open the system or make any
opening without permission.

(II) installation of
oil tank
1. After installation of oil tank, check for any
seepage. (carry out kerosene seepage test at
the welding seam between oil tank and relative
connecting pipe)
2. Steam heating pipe or cooling water passes
the hydrotest.
3. Installation oil level gauge.
4.carry out oil-immersing check on the buoy
5. Installation oil level ruler.
1. After installation, oil tank
should be free of leakage.
2. Test pressure should not
be less than 1.25 times of
the Max. Working pressure
of the medium.
3. Oil level gauge should be
equipped with obvious and
qualified oil level indicator.
4. Oil-immersing check
should be free of leakage.
5. Ruler should be vertical.
(III) installation of
oil pipe
1. Routing of the pipeline should be orderly and
reliable; do not embed the oil pipe in soil or
concrete.
1. Pressure oil pipe and oil
return pipe normally have an
inclination of 2%.
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Maintenance
item
2. Carry out leak test on valves in oil pipeline.
3. Padding of the joints between oil pipe and
associated parts should not extend to the inner
circle of the pipe; the thread joint should be
sealed by hemp thread and white paint.
4. Plane flange should be welded on both sides.
5. Check the oil sight glass and oil adjusting
device of bearings of ball mill.
2. There should be no
leakage.
3. Joints should be airtight.
4. Welded junction is free of
sand hole and crackle.
5. Oil sight glass is clear and
oil adjusting device
operates freely and properly.
(IV) oil cooler
installation
1. Check oil cooler oil side, water side.

2. Hydrotest should be performed for oil cooler.
1. Both oil side and water
side should be clean and
smooth; joint surface is free
of leakage
2. Test pressure should
be 1.25 times of the HP side
pressure.
(V) gear oil pump
check and
installation
1. Visually check the oil pump for any defect,
and check engagement of the gear.

2. Check the connection flange of end cover
and casing.
3. Measure clearances of parts.
1. Oil pump is free of defect
by visual inspection. Oil
pump gear engagement
should be stable and well
touched.
2. Connection flange should
be airtight.
3. Requirements of technical
specification should be
satisfied.
(VI)oil circulation 1. Install oil filter on the oil return header near
the oil tank.
2. Temporarily connect the pressure oil pipe and
oil return pipe of bearing during oil circulation to
prevent oil from passing through bearing.
3. Startup oil pump to establish normal working
oil pressure before oil circulation and check oil
tightness. Oil circulation should continue until
no debris on the screen. All parts should be tight
1. Mesh of the oil filter is
0.5- 0.7mm normally.
2. Mesh should be 0.30 mm.
3. There should be no rust
on the white cloth.
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Maintenance
item
without leakage.
4. Oil used for oil circulation is normal working
lube oil.
5. After oil circulation, recover pipeline and
remove debris inside oil tank; refill qualified lube
oil; then carry out oil circulation for the bearing.
Adjust oil volume to evenly coat the neck journal
with oil but the gland seal should be free of oil
leakage.
6. Install screen at the inlet oil pipe to the
bearing during oil filling test and test run.
7. During oil filling test, adjust the oil pressure
relay and safety valve as per technical
specification.
8. For dirty oil pipe, immersing acid cleaning is
recommended. After acid cleaning, blow with
steam and check inside of the pipe with white
cloth.
4.1.3.2 Maintenance of drive gear
Maintenance
item

(I)large/small
gear check
and
alignment
1. Remove gear seal housing and wash it.
2. Wash large gear and check for any crackle, burr,
depressed points or tooth falling. Check the gear
abrasion and teeth space by Template or tooth
calipers.
3. Check parallelism of the centerlines of large/small
gears.

4. Check the radial and axial vibration degree of
the large gear with dial gauge.

1. Gear seal housing
should be clean without oil.
2. When the abrasion
thickness of the chordal
tooth on gear pitch circle
reaches 5 mm, turn it
around for operation. When
another 5mm is worn,
replace it..
3. Non-parallelism of
centerlines of large/small
gear should not be larger
than 0.2 mm.
4. Radial and axial run-out
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Maintenance
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5. Measure addendum cone and gear backlash, the
number of measurement points for gear backlash
should be no less than 8. Record the average value
of clearance between working face and non-working
face.
6. Check the contact of large/small gear working
faces by color printing and correct the gear
deformation.
7. Check the engagement of the two semicircles of
the large gear and check the holding bolt on the joint
surface between the large gear and large tank
flange. Tighten it if necessary.
tolerance of the large gear
ring should satisfy the
following requirements:
radial swaying pitch
circle diameter0.25 mm.
axial swaying pitch
circle diameter0.35 mm.
5. Requirements not the
engagement of large/small
gear are:
addendum cone
clearance should be 6~8
mm.
gear backlash should not
be less than 1.40 mm, and
greater than 2.18 mm(when
width between centers is
greater than 2000-3150mm)
clearance error of the
working face along tooth
width is 0.15 mm.
6. Along tooth height is not
less than 50% and 60%
along tooth width.
7. Joint bolt should be tightly
secured without any rupture
or missing. Gear ring and
flange should be well
contacted, joint surface
clearance formed by gear
rings should be 0.1 mm.
(II) replace
large gear or
its working
face(turn it
1. Completely measure the large gear to be
replaced and record the result.
2. Remove seal housing above the large gear.
3. Turn the joint part of the two semocircles of the
1. The record should be
accurate and complete.
2.
3. The contact ratio between
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Maintenance
item
around) large gear to horizontal position. Lift the upper
semicircle by crane and securely drop it down after
disassemble all joint bolts. Avoid significantly
swaying during disassembling.

4. Turn the large tank 180 degree and drop down
the other semicircle.
5. Premount the semicircles of the new gear on
ground. Check the contact of the the two
semicircles with red lead oil and contact ratio of the
locating stud and cylindrical bore.
Clean the oil, rust, and burr on the gear and
flange joint surface before mounting
6. Measure tooth profile and teeth space of the new
gear with template and gear tooth calipers.

7. Lift and install the first semicircle of the new gear
to large tank.
8. Turn the large tank 180 degree to install the other
semicircle. Put in locating studs and bolts of the
joint surfaces of the two semicircles.
9. Put in joint bolts of the large gear and large tank
flange.
10. Check the contact of large gear joint surface
with filler gauge and adjust it if necessary. And then
one by one tighten the joint bolts of two semicircles
joint surface between the large gear and large tank.
11. Measure axial and radial swaying of the gear
with dial gauge. Evenly divide the large gear into
eight pats slowly turn the large tank, and one by one
measure the axial and radial swaying at the eight
dividing points (measure again for review). Carefully
record the results.
If the radial swaying degree does not satisfy
standards, radically adjust the large gear along
the locating stud of the joint
surface of the two
semocircles of the large
gear and the cylindrical bore
should be larger than 80%.
Contact ratio of the two joint
surfaces of the large gear
should be larger than 75%.
4.
5.
6. New gear tooth profile
and size should satisfy
the requirements of the
manufacturer drawings.
7.
8.

9. When measure the two
semicircles joint surfaces of
the large gear with 0.05 mm
filler gauge, there should be
no space to insert. Holding
bolt should be free of loose
and missing.
10. Radial and axial
run-out tolerances should
satisfy the following
requirements:
(1) radial swaying value is
1 mm.
(2) axial swaying value is
1.2 mm.

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Maintenance
item
large tank flange. If the axial swaying degree does
not satisfy standards, add wedge shim at the joint
surface of the large gear and large tank flange to
adjust it.
12. When both the axial and radial swaying degrees
satisfy requirements, put locating studs into large
gear and large tank flange. If the pin holes do not
match with studs, mill the hole again.
(III) measure
clearances of
small gear
parts
1. Disassemble bearing upper cover, and visually
check bearing.
2.measure the following clearance by filler gauge or
pressing lead wires:
Radial clearance between balls and bearing
inner and outer steel rings .
Axial and radial clearances between bearing
Outer ring and casing.

Axial clearance between thrust end and
expansion end bearing.
1. Bearing should be free of
corrosion or crackle.
2. Radial clearance is
between balls and bearing
inner and outer steel rings
should be 0.15~0.30 mm.
Radial clearance between
bearing outer ring and
bearing upper cover should
be 0.05~0.10 mm.
Thrust end axial clearance
should be 0.05~0.10mm;
expansion end axial
clearance should be 3~5
mm.
(IV)
disassemble
small gear
1. Check engagement of the large/small gear for
any match marking; mark if necessary.
2. Lift out small gear and put it on a prepared
support. Do not damage the ball bearing when
disassembling small gear.
1. Match marking should be
clear and complete.
(V)
maintenance
small gear
1. Clean small gear and neck journal with kerosene.
2. Check gear abrasion and teeth space with
template or gear tooth calipers; knock gears one by
one to check for any crackle.

3. Correct the deformation on the tooth surface.
1. Turn around the gear
pitch circle when tooth
thickness abrasion reaches
3~5 mm and replace it when
another 3~5 mm is worn.
2. Gear shaft should be free
of crackle. Shaft tortuosity
should be <0.1 mm,
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Maintenance
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4. Shaft should be free of crackle and loosing. If
abnormal noise is found during operation, measure
tortuosity of shaft, ellipticity and conicity of the neck
journal and record the results.
5. Check hardness of the small gear teeth and
decide whether to anneal the surface based on the
gear abrasion.
ellipticity <0.03 mm and
conicity < 0.015mm.
3. Quenching hardness of
the small gear surface Rc
should be 40-45.
Quenched case depth
should be 15 mm.
(VI) check
ball bearing
1. Check balls, balls retaining support and inner/
outer steel ring for any crackle, peeling and stain;
check abrasion of the retaining support.

2. Check the match of the ball bearing inner steel
ring and shaft.
1. Balls should be free of
crackle and serious stain.
Balls windage should be
<0.30 mm. Keeper and
inner/outer steel rings
should be free of crackle.
Replace keeper when its
abrasion exceeds 1/3 of its
thickness.
2. The assembling of ball
bearing inner steel ring and
shaft should not be loose
and should have a stress of
0.01-0.03mm.
(VII) replace
ball bearing
1. Disassemble ball bearing with special tools.
2. Grind the rust and burr on the neck journal by
abrasive cloth or oil stone.
3. Check parts of new bearing for any crackle or
rupture and measure windage of balls.
4. Measure the mating dimension of inner ring of
new bearing and neck journal.
5.put the bearing into lube oil and heat it unto
100-120 and quickly put into the original position
on the shaft against the shoulder (no clearance) for
natural cooling.
1. Parts of new bearing
should be free of crackle
and rupture. Windage of
balls should be uniform and
0.3 mm.
2. Tightening force between
bearing and shaft should be
0.01~0.03 mm.
3. After cooling, ball bearing
should be rotated freely by
hand.
(VIII) check
and replace
bearing
1. Check whether gland packing is flat, soft and
elastic, and check for any crackle,.
2. Check abrasion of the gland packing and the
1. Seal packing should be
flat, soft and elastic without
breach.
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Maintenance
item
packing contact with shaft. Replace outworn parts. 2. Contact of the seal
packing and shaft should be
tight but not over tightened
(1 mm of overtghtening is
allowable).
(IX)
assembling of
small gear
1. Lift the assembled small gear with lifting tools
onto the bearing housing.
2. Place the small gear as per matching mark. Align
the small gear as per addendum cone and gear
backlash.
3. Check engagement of the large/small gears with
red lead powder.
4. Measure the radial clearance between ball
bearing outer steel ring and bearing cap with filler
gauge or pressing lead wires.
1. Stress between the small
gear and shaft should be
0.03~0.05 mm.
2. Gear backlash of the
engagement between
large/small gears should be
0.75~1.5 mm. Difference
between the measured gear
backlash values on both
side should be
0.05~0.10 mm.
3. Contact area of the
large/small gears should be
75%.
(X)
installation
bearing cover
and gear
seal housing
1. Move the small gear to make thrust ring cling to
thrust shoe; install bearing cap and symmetrically
tighten bolts.
2. Repair deformation and rupture of the gear seal
housing.

1. Surfaces of the upper and
lower bush cover thrust
should be on the same
level.
2. Seal housing should
intact without deformation;
connecting screws on the
cover should be tightly
engaged; flange should be
flat and tight without oil
leakage.
Packing seal should be
properly tightened.
Seal housing should not
crash with the gear.
(XI) check
and tighten
anchor bolt
1. Check anchor bolt for any loose or rupture.

1. Anchor bolt should be
free of loose, rupture and
missing.
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Maintenance
item
2. Check nut for any loose with wrench. Should
tighten it with lock nut if necessary.
2. Bolt should be well
tightened without loose.
4.1.3.1 cylinder and lining plate maintenance
Maintenance
item
, maintenance
of steel ball coal
mill
(I)pour out steel
balls

1 startup coal pulverizer and mill exhauster
to run without load for 15 minutes to exhaust
residual pulverized coal in the cylinder.
2. Remove inlet hopper, securely install the
tools for scrapering out steel balls and the
screen for separating steel balls.
3. Startup coal pulverizer; steel balls in the
bucket will go into the screen when the large
tank rotates. By the screen, large and small
steel balls( and scrap iron, debris) are
separated and transmitted to the outlets .
4. Small steel balls and scrap iron, debris will
be delivered to a specified location.
5. Handle the qualified steel balls to a
specified stack yard.
1,inside of cylinder should
be free of powder
accumulation

2, installed equipment should
be secured reliably.

3, steel balls with a diameter
less than 20 mm should be out
of service.

(II) maintenance
of the inlet/ outlet
hoppers
1. Measure the abrasion of the hopper
guarded plate.
2. To prolong the service life of the outlet
elbow the two following measures are
recommended:
(1) Install a wearing steel plate of 10 mm at
the bottom of the elbow. It can work for a
minor overhaul period.
(2) Grout alumina cement in the elbow. Weld
hook nail at the back of the elbow and coat it
with steel wire gauze; then grout alumina
cement of 50 mm and care it for a week. It
wont be worn out during two years by this
means.
1, when the abrasion of the
hopper guarded plate exceeds
the 2/3 of the former thickness,
replace it. Partial abrasion
should be repaired and the
surface should be kept flat.
2. Inner surface should be
kept flat.
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Maintenance
item
(III) disassemble
coupling and
studs
1. Check coupling for any match marking.
2. Check coupling bolts. Coat it with butter
or black lead powder after derust; tighten the
nuts; it should be carefully stored after
matching.
1, match marking should clear
intact.
2, bolts and nuts should be
free of crackle; thread should
be intact.
(IV) check steel
tiles and
holding screw
1. Check abrasion and crackle of the steel
tiles.

2. Manually knock the steel tiles bolts to
check their tightness.
1. If the abrasion of steel tiles
exceeds the 2/3 of the
thickness, it should be
replaced. Replace steel tiles
with crackle and unable to be
repaired.
2. Bolts after tightening should
satisfy requirements without
loose.
(V) replace steel
tiles
1. When replace all or part lining tiles, I beam
overhead crane should be installed for steel
tiles entering or leaving large tank and
completely check the large tank.
2. Review the external dimension of the new
tiles as per drawings and check their
connection; number the steel tiles and
record.
3. When replace steel tiles, turn the steel tiles
bolts to the horizontal positions; then
dismount the lower steel tiles. During
installation, lay asbestos slate with a
thickness of 5-10mm between the tank and
lining plate; Concave-convex joints of the
steel tiles should be tight; adjust clearance of
the steel tiles with tommy bar; do not cut the
steel tiles without permit. Because the
abrasions of the steel tiles at the inlet and
outlet surface are different, exchange the
tiles after a period of operation.
4. Press the steel tiles with wedge iron block
and tighten bolts before turn the large tank
180 degree. Dismount the other part of the
1. Large tank should be free of
crackle and plumping.
2. New steel tiles should be
free of crackle and casting
defects, their sizes should
satisfy requirements.
3. Laid asbestos slate should
be uniform and the joint seam
should be tight. After
installation, steel tiles and
large tank inner wall should
contact completely. Clearance
of steel tiles should be kept
uniform.

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Maintenance
item
steel tiles as per above said procedures.
Lowly turn abround the large tank to avoid
centre-of-gravity shift of the large tank.
5.during construction, to avoid rotation of the
large tank, motor of the slow drive device
should be shut down. Staff should be
appointed for monitoring and protection; weld
temporary support at the outer wall of the
large tank.
6. After replace new tiles,install steel balls in
groups. The quantity of the balls install at the
first time should be 20-30% of total. Number
of each group should not exceed 20% of
total. After each installation, operate for 5
mionute without load and tighten again the
steel tiles bolts; after 72 hours operation,
retighten them again; the same check should
be performed at each minor overhaul.
(VI) check tank
end cover and
associated bolts
1. Check tank manhole for any crackle; repair
it if necessary.
2. Check the root of the end cover bar and
bolts for any crackle; repair or replace it if
necessary.
3. Verify joint bolts of large tank and end
cover are properly tightened.
4. Verify joint bolts of the geared ring and
tank are secured.
1. If penetrable crackles exist
with a number exceeds the 1/3
of total bolt, replace it.
2.

3. Bolts should be free of
defect and joint bolts should be
well tightened.
4. Bolts should be free of
defect and joint bolt should be
well tightened.
(VII) jack up tank,
disassemble
bearing bush and
check(only for
abnormal case
during operation)
1. Dismount the large bush cover and lift it
the work piece and record.
2. Measure and record the clearances
between large bush and parts of tubular
journal.
3. Jack up the large tank until the large bush

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Maintenance
item
can be turned out. Crosstie and taper liner
should be put below the large tank when jack
it up. Jacking should be slowly performed
and tank shift should be avoided.
4. Lift the large bush with hoist by binding it
with wire cables; then turn around tubular
journa. Do not damage the surface of the
bearing pad.
5. Cover the tubular journal with white cloth
and plastic cloth.
(VIII) check and
rescraping of
the main shaft
bearing pad and
tubular journal
1. Wash the surface of the bearing pad with
kerosene; check bearing pad for any crackle,
sand hole and burnt part; knock the bearing
pad ot check for any shelling. Bearing pad
can be repaired with babbitt.

2. Rescraping of the main shaft bearing pad:
(1) Mark a 75 degree rim anglenoundary on
the bearing pad.
(2) Evenly rescrape off 0.01~0.03 mm
outside the secondary boundary.
(3) Rescrape the bearing pad within the
range of rim angle.
(4) Rescrape off 0.03~0.05 mm from the
boundary to the position 15 mm from the
secondary outer side.
(5) Move outwards 15 mm gradually and
rescrape off 0.03~0.05 mm until the centering
surface.
(6) Rescrape the stepped clearance to
wedge clearance.
(7) Rescrape the bearing bore to an ellipse.
3. Tubular journal should be checked in
1. Bearing pad should smooth
and intact without any crackle
or pocking mark. When the
shelling area of the bearing
pad exceeds specified value,
repair it. No shelling in the
range of rim angle is allowable.

2.1 Rim angle of the large
bush should be in the range of
705.
2.3 Bearing pad and neck
journal should be contacted
evenly; check by means of
color printing and there should
be at least 1~2 points on every
square centimeter area.
Contact area should be over
85%. The contact point should
be hard and clear. Position
without points should be
rescraped 2-3 times more for
better lubrication.
2.4 Sun of the clearances of
the bearing bores normally
should be 1.5~2/1000 of the
diameter of the neck journal;
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Maintenance
item
aspect of :
(1) Check diameter of the hollow tubular
journal.
(2) Check the flatness of the tubular journal
surface along axial direction. Axially stick
the ruler to the shaft surface to be parallel to
centerline of the the shaft. Then check filler
gauge. The measured difeerence between
concavo and convex parts of the shaft is the
flatness error. Grind the surface if the error
exceeds limit.
(3) Check ellipticity of the tubular journal
which is half of the deference between long
shaft diameter and short shaft diameter.
(4) Check conicity of the tubular journal.
(5) Check the damage and corrosion of the
tubular journal surface. When the partial
damage or corrosion is within the following
ranges: width less than 5 mm, length less
than 100 mm, diameter less than 15 mm, pit
depth less than 0.2 mm, rust spot depth less
than 0.2 mm and total corrosion area less
than 5% of the neck journal working face
area, treat it with oil stone or abrasive cloth or
grinding tools for neck journal. If the
glossiness is low, treat it with polishing
method.
(6) Check the nonconcentricity of the two
sides of the neck journal. Centimeter also
can be used to check on the main bearing
end face and the runout value should be less
than those specified in the right table.
4. Clean, check main bearing spherical bush.
Spherical bush is the key part of the coal
pulverizer and should be checked strictly;
ensure the spherical bush and spherical seat
contact securely and evenly. It works agilely.
and there should be a ligulate
oil drain clearance.
3.1 Diameter error of the
tubular journal should be less
than 0.15/1000 of the designed
diameter.
3.2 Flatness errors should be
less than 0.05 mm.
3.3 Ellipticity should satisfy the
requirements of equipment
technical documents and not
greater than 0.2 mm.
3.4 Conicity should satisfy the
requirements of equipment
technical documents and not
greater than 0.2 mm.
3.5 Surface should be smooth
(required to reach R=7m)
without rupture or rust.
3.6 The main runout value of
the bearing surface is shown in
the right table.
4. Bearing sphere action
agilely with good contact.
Check by means of color
printing and there should be no
less than 1-2 points on one
square centimeter, and the
contacting area should not be
less than 75%. On the two
sides of the contact surface,
there should be a wedge
clearance as shown below:
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Maintenance
item
Check the contacting by means of color
printing method. Contact points should be
hard; scrap 2 or 3 more times the position
without color point; grind the upper and
lower contact surfaces of the spherical bush
with #00 fine sand cloth to improve surface
glossiness and reduce friction. Coat the
surface with butter after rescraping.
5. Clean main bearing inner wall,
upper cover, oil sink, oil hole and oil return
hole.
Hydrotest should be carried out for the main
bearing water chamber.
6. Currently temperature of the measuring
points at the coal pulverizer bearing pad can
not correctly represent the temperature of
bearing pad babbitt. The reason is the babbitt
can not be directly measured. So it should be
checked. Directly weld the measuring
points on the joint of the iron and babbitt to
actually measure the babbitt temperature.

Note: depth a should be
20-25 mm, edge clearance c
should be 0.20-1.5 mm.
5. Completely clean cavities,
oil sink and inner wall to
ensure the smoothing of the oil
pipe. Hydrotest pressure
should be 1.25 times of the
working pressure of the
cooling water.
(IX) recover ball
mill
1. Clean large bush surface, spherical bush
(seat) and tubular journal and coat butter on
the spherical bush. Before lower down the
tan, put three dial gauges on the main
bearing foundation to measure the variation
of the three points on the left, middle and
right of the lower bottom surface of the main
bearing before and after tank location
bearing.
2. Lift the large bush with two hoists and
turn it below the hollow shaft along the
direction of the tubular journal and locate it as
per matching mark. When descend the
large bush, it should be ordered by an
appointed person; check the clearance
around the bush and tubular journal every
10 mm descending until it is securely located
1. Elevation error of the main
bearing should be 10 mm;
horizontal error of two bearings
should be 0.5 mm/m;
distance error between
bearings should be 0 mm;
distance between two bearings
should be determined as per
actual size of the tank and take
into consideration of the hot
expansion; bedplates of two
bearings should be parallel
with a diagonal error 2 mm;
longitudinal and transverse
horizontal error of bedplate
should be not greater than
0.1/1000 of its length and
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Maintenance
item
bush surface should be protected from
damage during installation. Align the
bearing after location and measure the
horizontal error of the two bearings.
3. Before location of tank, completely clean
bush surface and oil sink. Before large tank is
lowered down to the surface of large bush fill
in #100 lube oil of 1-2 liters along tubular
journal to protect large bush surface.
4. Locating tank should be carried out stably
and two ends should be in place at the same
time. After location of the tank clearances
should satisfy the following requirements:
(1) Marking line on the templates on the two
side of the tubular journal should be aligned
with the positions of the left, middle and right
related to the large bush:

Chinese English
left
middle
right
(2) Clearance between bearing pad and
hollow shaft radial:
width.
2. Centers of the spherical
seat spacer pin and spherical
bush spacing hole should be
aligned; bearing should be
kept level at the directions of
longitudinal and transverse;
horizontal error of two bearings
should be 0.5 mm.

4.1

4.2 Radial clearance a, b, c, d
should be equal.

4.3 Large tank horizontal error
should be 0.50 mm.
4.4 tubular journal and large
bush two sides clearance
should satisfy requirements in
the following table:
Thickness
of filler
gauge
(mm)
Insert
length
(mm)
0.15 600-650
0.50 500-550
0.75 400-450
1.00 300-350
1.25 200-250

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Maintenance
item

(3) Measure levelness of the large tank.

(4) Measure the wedge clearance between
tubular journal and two sides of the large
bush with filler gauge.
(5) After tank in place, check and adjust the
axial expansion clearance and thrust
clearance.
4. Install the packing seal at the bearing
bore and then the large bush cover.
4.5 Recommended value for
the expansion clearance of the
supporting bearing is shown in
the following table:

Chinese English
neck journal
bearing
Total thrust clearance error is
0.15 mm.
Thrust clearance is 0.2~0.4
mm normally.
4. Bearing bore should be
tight without seepage.
(X) check and
clean cooling
water system
1. Check cooling water pipe and clean the
blockage (if any), then blow it with
compressed air.
2. Maintenance of flanges and valves.
1. Cooling water pipe should
be free of blockage and
leakage.
2. Flange is intact and
operation of valve is agile and
it is tight without leakage.
(XI)dismounting
and installation of
sound insulation
of the large tank
1. When replace steel tiles, remove all sound
insulation layers and check it.

2. When repair the cover plate or bolts of the
sound insulation layer by means of gas
1. Sound insulation layer
should be tight with a thickness
of 40~70 mm.
2. When recover sound
insulation layer, they should be
laid orderly. Stress on bolts
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Maintenance
item
welding, remove a part of felt of the internal
sound insulation or water the parts to be
cut/welded to avoid fire.
should be uniform and bolts
should be sufficient.
(XII) installation
of steel balls
1. Install the tools for installing balls and put
in a certain number of balls with certain sizes
as per adjusting results or specifications.
1. Steel balls with a diameter
less than 25 mm and debris
should be kept out of coal
pulverizer; application of steel
balls made by cast iron should
be prohibited.
(XIII) recover
large tank
inlet/outlet elbow
and sealing
device
1. Recover inlet/outlet elbow, measure and
record the axial and radial clearances
between elbow and hollow sleeve.

2. Recover sealing device and tighten all
bolts.
3. Install sheet iron of the explosion door
and coat it with a layer of white paint. Put
asbestos cord with diameter of 5 mm on the
flange of the explosion door before install
sheet iron and tighten bolts.
The matching of the hopper
and hollow sleeve should
satisfy the following
requirements:
U
nit

Thru
st
side

Exp
ansi
on
side
Axial
clearan
ce
M
m
<3 15
Radial
clearan
ce
M
m
1~4 1~4

Center
error
M
m
<1 <1
2. Flange bolts should be intact
and well tightened. Contact
of packing and sealing pad
should be tight with uniform
clearance around.
3.sheet iron of the explosion
door should be made by
tinplate or white iron with a
thickness of 3-0.5 mm.
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Maintenance
item
(XIV) check
wedge and
anchor bolts of
the bedplate
1. Manually knock the bedplate to check for
any crackle and use magnifier if necessary.
2. Check wedge for any loose. Pin can be
used by drilling hole to avoid displacement.
3. Manually knock the anchor bolts to check
for any crackle, rupture or loose. Tighten it
if necessary.
1. Bedplate should be free of
crackle.

2. Wedge should be free of
loose.
3. Anchor bolt should be free of
crackle or other defects and
well tightened
IV system test
run:
(I) prerequisites
for ball mill test
run
1. Installation, oil circulation and filling oil test
have completed.
2. Oil pressure interlock test of ball mill and
oil system has completed.
3. Test run should be performed as per
specified technical specifications prepared
before test run.
4. After no-load test run of motor is accepted,
run for two hours together with reducer.

(II) startup
requirement for
ball mill
1. Startup oil system and adjust it to normal
operation.
2. When tank is properly started up, shut it
down through emergency button. Check
main bearing and driver for any abnormal
condition and begin no-load test run.
3. Before install steel balls, 8 hours no-load
test run should be accepted. Installation of
steel balls should be performed as per
equipment technical specifications and
should satisfy the following requirements:
Steel balls should be weighted.
Balls should be installed by groups. The
quantity of the balls install at the first time
should be 20-30% of total. Number of each
group should not exceed 20% of total a test
run should be carried out after each
installation of balls to evenly distribute the
1.
2.

3.New steel balls should be the
following percentage:
40 mm 30%
50 mm 35%
60 mm 35%

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Maintenance
item
balls; record the vibration value of parts and
motor current.
Stop installation of the balls if any
abnormal condition is found; continue test
run after faults are cleared.
After test run of balls installation, check the
engagement of the large gear and then
tighten lining plate bolts one by one.
(III) measurement
and check
during test run
1. Measure vibration of parts.

2. Measure temperature of parts.

3. Check the leakage of bearings.
1.1 Two bearings of the motor:
0. 05- 0.10 mm.
1.2 Two bearing of the reducer:
0.08-0.12 mm.
1.3 Two bearing of the small
gear:
0.08-0.15 mm.
1.4 Large tank and large bush:
0.05-0.15mm.
2.1 Large bush bearing pad
temperature should be 50 .
Temperature of the mixed
return oil should be 40 .
2.2 Bearing temperature of
the small gear reducer should
be 70 .
2.3 Bearing of parts should be
free of oil leakage.
Main maintenance tools and spare parts for steel ball coal mill
(I) Main maintenance tools:
Micrometers for inner and outer diameters, centimeter, large hammer, four 50 tonnes spiral
jacks, two supporting seats (for jacking large tank), special tools for turning bearing pad.
(II) User drawings and information list:
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Serial No. Code Name Pages
1 K4419.00 SM BBI4796 steel ball coal mill (left) 2
2 K4419.1.0 SM Foundation and embedded part (left) 1
3 K4419.2.0 SM Drive part (left) 1
4 K4419.2.1.0 SM Small gear assemble 1
5 K4419.2.2.0 SM Large gear device 1
6 K4419.2.3.0 SM Slow drive device (left) 1
7 K4419.3.0 SM Cylinder part 1
8 K4419.4.0 SM Lining plate part (left) 1
9 K4419.5.0 SM Main bearing part A 1
10 K4419.6.0 SM Feed hopper part (left) 1
11 K4419.7.0 SM Inlet spiral pipe (left) 1
12 K4419.8.0 SM Inlet spiral pipe 1
13 K4419.9.0 SM Outlet hopper part 1
14 K4419.10.0 SM Large gear cover 1
15 K4419.11.0 SM Noise enclosure (left) 2
16 K4419.11.1.0 SM Noise enclosure bottom plate(left) 1
17 K4419.11.2.0 SM Noise enclosure frame (left) 2
18 K4419.12.0 SM Large gear sealing air device (left) 1
19 K4419.13.0 SM Main bearing lube oil system 1
20 K4419.14.0 SM Main motor lube oil system 1
21 K4419.15.0 SM Ball washer 1
22 K4419.16.0 SM Main bearing part B 1
23 K4419.21.0 SM General chart reducer and its oil station 1
24 K4419.22.0 SM General chart of reducer and its oil station 1
25 K4419.23.0 SM Main bearing lube oil station installation drawing 1
26
K4419.24.0 SM Chematic diagram of Main bearing lube oil station
system
1
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27 K4419.25.0 SM Main motor lube oil station installation drawing 1
28
K4419.26.0 SM Schematic diagram of the main motor lube oil
station systems
1
29 K4419.27.0 SM Large gear lube oil spray system drawing 1
30 K4419.29.0 SM Crowned teeth coupling 1
31 K4419.30.0 SM T type spring coupling 1
32 K4419.31.0 SM Motor list (each mill) 1
33 K4419.32.0 SM List of high strength bolt (each mill) 1
34 K4420.00 SM BBI4796 steel ball coal mill (right) 2
35 K4420.1.0 SM Foundation and embedded part (right) 1
36 K4420.2.0 SM Drive part (right) 1
37 K4420.2.1.0 Slow drive device(right) 1
38 K4420.3.0 SM Lining plate part (right) 1
39 K4420.4.0 SM Feed hopper part (right) 1
40 K4419.5.0 SM Inlet spiral pipe (right) 1
41 K4420.6.0 SM Noise enclosure (right) 2
42 K4420.6.1.0 SM Noise enclosure bottom plate (right) 1
43 K4420.6.2.0 SM Noise enclosure frame (right) 2
44 K4420.7.0 SM Large gear sealing air device (right) 1
45 QK4419.00 Electrical drawing information 75
46 KF4419.00 SM
List of spare parts and special tools for BBI4796
steel ball coal mill
12
4.2 Coal Feeder
4.2.1 Coal Feeder Technical Specifications
Coal feeder is made up of body, feeding belt mechanism, chain scraper, weighting
mechanism, signal unit for coal blockage and lack, lubrication device and electrical conduits,
control cabinet and power supply cabinet. Coal enters coal feeder from raw coal hopper via coal
gate, and is transported by belt to the outlet of feeder. Two weighting carrier roller are installed
inside coal feeder forming a weighting span. A weighting roller is at the middle of the weighting
span, equipped with load sensor. A speed sensor is installed on the main belt for measuring
transporting speed and calculating coal feeding volume.
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Coal feeder main technical parameters:
RMSD100 type, output 30~110 t/h
4.2.2 Coal Feeder Maintenance
Maintenance
item
(I) Maintenance
preparation
1. Cut off power supply of coal feeder and
close inlet gate.
2. Open the front and back door of the
coal feeder; clean raw coal adherent to
the coal feeder belt; start up chain
cleaning mechanism to clean the
accumulated coal at the bottom of the
coal feeder tank.

( II) Disassemble
tension roller

Loose the tension bolt of the tension roller
to the largest position. Remove the
grease hose of the tension roller.
2. Remove weighting sensor weighing
rollers.
3. Place a cushion block under the
tension roller and remove the roller rail
and the joint bolts of bearing housing and
casing; pull out tension roller from the
side door.
4. Remove and check bearing housing
and bearing on the tension roller.
1. Loosing bolt should be
carried out alternatively to
avoid thread damage.
(III) Belt
disassemble
After remove belt driving roller, draw out
the belt from the outlet door of the coal
feeder.

(IV) Assemble
and adjust roller
and belt

1. Place the belt into casing.
2. Install two sides tension roller arms
together with sleeve and bolt onto the
casing and secure it with cotter pin.
3. Connect the upper and lower lead rails
with casing by bolts and install belt
supporting plate on the lead rail.
4. Wash roller surface, roller bearing and
L roller surface should be
smooth without any burr or
defect.
2. Roller bearing should be
free of abrasion or corrosive
pitting.
3, tension arm sways agilely.
4. Two sides of the upper and
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bearing unit with diesel and check the
above parts.
5. Put the bearing and bearing assembly
onto the roller shaft.
6. Put sliding block onto the tension roller
and put it onto the belt inside casing and
locate it on the upper and lower lead rails.
Note: bearing housing is filled with #3
lithium saponify .
7. Installation tension stay bolt and bolt
seat and then move the tension bolt to its
long position.
8. Put the disassemble seat of the roller
into the belt and casing and secure it.
9. Slide the drive roller into the casing
and secure the roller onto the casing with
bearing housing cap. Adjust the elevation
of the roller by the adjusting nut on the
bolt of the drop hanger.
11 insert the driven roller into the casing
via maintenance hole on the side
casing surface and locate it. When
adjust tension bolt, tighten the belt to a
suitable tension degree.
12. Assemble belt and clean the scraper.
lower sliding rail should be on
the same level.
5. Sliding block of the tension
bolt should move agilely in the
lead rail.
6.
7.
8. There should be a
clearance of 3mm between
the half coupling on roller and
that on reducer.
(V) assemble and
adjust weighting
mechanism

1. Wash weighting roller and roller
bearing assembly with diesel.
2.Mount the roller and associated parts
lick bearing , bearing housing onto the
casing.
Note: bearing housing should be filled
with #3 lithium saponify .
3. Unite the weighting roller and two sides
bearing assembly.
Note: bearing housing should be filled
with #3 lithium saponify .
1. Roller surface should be
glossy without burr, and the
supporting contact surface
should be free of friction.
Roller should rotate agilely
without seizing; axial runout
value should be less than
1.5mm; runout value of the
outer circle should be less
than 1mm.
2. There should be not friction
between the lipping of the belt
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4. Install weighting sensor at the two
sides of the casing and secure it with nut.
connect the assembled weighing
rollers with the two sides weighting
sensors with pin roll ; pin roll should be
equipped with cotter pin.
5. Install the standard weighting
calibration block on the weighting bearing
housing with joint plate and pin and lock it
with cotter pin.
Note: operating handle should rotate
agilely; the joint plate of the standard
weighting calibration block and bearing
housing of the carrier roller should be
clung to them without limit.
and weighting roller or
weighting carrier roller.
(VI) disassemble
reducer casing

1. Drain out lube oil inside the reducer
casing and remove the coupling and
motor from the casing.
2. Remove bolt s of the bearing circular
gear seat of the reducer casing to
dismount the bearing housing.
3. Remove angular tooth, nut and washer.
4. Remove bottom bearing housing; take
out lube oil pump, spring and spring seat.
5. Remove circular gear and take off
worm wheel shaft.
6. Remove angular tooth and front & back
bearing housings of the worm wheel; take
out worm wheel and remove worm wheel
and bearings on the worm wheel.
Note: frame heating can be used to
remove parts.
7. Take out worm wheel and bearing outer
ring of the worm from bearing housing.
8. Take out oil seal from the worm bearing
housing of the worm wheel.

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(VII) assemble
reducer casing
1. Install the oil seal into worm wheel
bearing housing.
2. Install the outer ring of the worm
bearing and that of the worm wheel
bearing into bearing housing.
3. Put the inner ring of the worm bearing
and that of worm wheel bearing onto the
worm and worm wheel shaft and knock
them to the shaft shoulder.
4. Install the worm wheel into reducer
casing and measure the windage.

4.3 Maintenance of the Auxiliary Equipment of the Coal Pulverizing System
4.3.1 Maintenance of the Raw Coal Bin and Pulverized Coal Bunker
4.3.1.1 Raw Coal Bin and Pulverized Coal Bunker Technical Specifications
Raw Coal Bin Technical Specifications
Boiler is equipped with two raw coal bins, which is the raw coal storing equipment of the
coal pulverizing system. Its upper part is a rhombus shape rhombus with four wall inclination
angle 30; its lower part is a hyperbola metal coal hopper. After primary crashing by the coal
crusher in the coal stack yard, raw coal is delivered to the raw coal bin for storage by the
conveyor belt.
Structure of the raw coal bin is shown below:
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Fig 5-3 Structure of the Raw Coal Bin
4.3.1.1 Pulverized coal bunker technical specifications
Boiler is equipped with two pulverized coal bunkers, which are used for storing pulverized
coal made by the coal pulverizing system. Its structure is similar with raw coal bin ;
To avoid powder accumulation, corners are made into arch-shape. It is sealed around
and equipped with dehumidifying pipe, firefighting steam pipe, carbon dioxide pipe and
explosion door on the ceiling together with powder level indicator. Pulverized coal separated
by the fine pulverized-coal separator enters the pulverized coal bunker via air locker, wood
scraps separator.
4.3.1.2 Raw Coal Bin and Pulverized Coal Bunker Maintenance
Maintenance of raw coal bin
(I) clean the bin Equipment department should contact
the fuel department to clean the bin.

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(II) maintenance of the
metal coal hopper
Check abrasion of the metal coal hopper,
repair the position with over abrasion or
leakage.
Thickness of the coal
hopper steel plate
should be 4 mm; after
maintenance, raw coal
bin should be free of
leakage and abrasion.
Maintenance of pulverized coal bunker
Maintenance
item
(I) preparation
before
maintenance
1. Prepare cleaning tools and small animals (chicken
or duck).
2. Prepare lighting tools. To ensure safety, 12 V
portable light should be used and insulation of rubber
cable and lamp cap should be good. Before boiler
shutdown, prepare steam and carbon dioxide
firefighting equipment for emergency.
3. Pulverized coal bunker should be empty and work
sheet has been issued.
4. Before cleaning, close valves of all pulverized coal
chute and firefighting pipes and lock out and tag out.
5. Open manhole to vent naturally for 24 hours; the
manhole should be enclosed by white/red strips.
6. Temperature should be kept below 40 ; attention
should be paid to the temperature of the pulverized
coal to prevent explosion caused by pulverized coal
combustion.

(II) clean coal
bin
1. Put the small animals inside the pulverized coal
bunker for abut 1 hours to verify the environment is
safe for staff.
2. Flammable matters and other debris are prohibited.
Maintenance staff should wear special work clothes
and shoe without iron. Safety belt should be Worn
before enter the coal bin and the end of rope should
be out of the coal bin; there should be two or more
personnel responsible for monitoring and protection.
Personnel should not enter the bin two or more at the
same time; the time inside the bin should not exceed
10 minutes. Coal shovel for cleaning bin should be
1.

2. After cleaning,
internal wall and
corners should be
free of
accumulated
pulverized coal.

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made by copper or aluminum to avoid causing spark.
3 personnel should well gas mask, safety spectacles
and glove; cuff and bottom of trousers should be
bound.
4. Check moisture absorption piping, firefighting
steam pipe, and carbon dioxide pipe and explosion
door.
5. During cleaning, if spontaneous combustion of
pulverized coal is found, stop cleaning immediately
and leave the bin quickly to close the bin and
extinguish the fire.
6. Personnel of safety supervision department and
medical staff should be on site during cleaning.
7. Before removal of pulverized fuel feeder, cleaning
staff s should leave pulverized coal bunker.

3.

4. All should be
smooth and intact.
(III) close
manhole
1. After cleaning, check the amount of staff and tools
avoiding foreign matters left in the bin.
2, manhole joint surface should be sealed with
asbestos cord; flange bolts should be complete and
evenly tightened.
3. Outer wall of the pulverized coal bunker missing
insulation should be repaired.
1.

2. There should be
no powder
leakage.
(IV) calibrate
powder indicator
1. Check the powder level indicator; it should be vivid
with secure installation. Except operating rope, there
should be safety rope on the powder indicator.
2. Check adjusting height of the powder indicator
3. Check wire cable and pulley
1. Calibrate and
verify the indication
of the indicator
matches the actual
powder level.
2. Powder
indicator's
adjusting height:
high limit is
500mm to the top
of the pulverized
coal bunker and
the lower limit is
200mm to the
bottom
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4.3.2 Coarse /fine pulverized-coal separator
4.3.2.1 Technical specifications of the coarse /fine pulverized-coal separator
TPRI-SZ series biaxial course Pulverized-coal Separator
(I) Equipment introduction:
TPRI-SZ series serial biaxial course Pulverized-coal Separator is one of the important
equipments of the coal pulverizing system. It is used to separate the pulverized coal made by
coal pulverizer. Main technical features of the TPRI-SZ series serial biaxial coarse
Pulverized-coal Separator is: a stage of axial baffle is added between the inner and outer cones
of the axial type coarse Pulverized -coal Separator against the shortcomings existing in the
axial type and radial type coarse Pulverized-coal Separator pulverized coal. Air flow is made
to rotate from the lower baffle extending the distance of rotation, enhancing the separation and
improving the uniformity of pulverized coal; it is beneficial to the combustion of the pulverized
coal in the furnace and to the improvement of the utilization rate of the pulverized coal so as to
improve the economy effect of the boiler.
Its operating Principle is, pulverized coal air flow out of coal pulverizer enter the TPRI-SZ
series serial biaxial coarse Pulverized-coal Separator from its lower part. It moves upwards.
While the flowing section enlarges, the flow decreases. Therefore, part of coarse powder is
separated by gravity. The remaining pulverized coal air flow enters the inner cone via deflector
baffle. Rotating pulverized coal air flow is separated again by the centrifugal force; qualified
pulverized coal air flow passes the bushing at the top and the fine pulverized-coal separator into
the pulverized coal bunker; unqualified coarse pulverized coal returns to the coal pulverizer via
air locker for further grinding.
(II) Equipment specifications:
Size: TPRI-SZ series serial biaxial coarse pulverized-coal separator
Type: Explosion proof & centrifugal
Quantity: 2
Deflector baffle: 32
Structure: shown below:
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Structure diagram of TPRI-SZ series serial biaxial coarse Pulverized-coal Separator
HL-GX series high efficiency fine pulverized-coal separator
(I) equipment introduction:
Fine pulverized-coal separator is equipment in the coal pulverizing system used to
separate pulverized coal and air from the pulverized coal air flow coming from HL-GX series
high efficiency fine pulverized-coal separator. Its operating principle is: pulverized coal air flow
enter fine pulverized-coal separator along the tangential direction and rotate in the cylinder of
the separator. Under the action of the centrifugal force, pulverized coal is thrown to the cylinder
wall and drops down. Then it enter pulverized coal bunker through air locker, wood scraps
separator. While air is induced out via center cylinder and sent to the furnace by mill
exhauster.
( II) equipment specification:
Specification: HL-GX high efficiency fine pulverized-coal separator
Type: explosion prevention & centrifugal
Quantity: 2
Structure is shown below:

4.3.2.2 Coarse/fine separator maintenance
(I) Preparation 1. Before shutdown, check and record air
leakage.
2. Prepare maintenance and lighting tool.
3. After work sheet is issued, open manhole

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and explosion door for natural ventilation.
4. Steel plate for repairing weld should be
ready.
5. Before shutdown, empty the powder
accumulation inside coal pulverizer.
(II) check internal
abrasion
1. After verify the internal air is fresh and
the safety measures are correct, for
convenience of the check and repair
activities, scaffold is to built up and be
accepted.
2. Before enter TPRI-SZ series serial biaxial
coarse Pulverized-coal Separator, test
should be carried out on small animals.
3. Enter through manhole (or explosion
door) to remove internal powder
accumulation, check and record abrasion of
the inner /outer cone, pipe and support of
the inner cone. Parts with abrasion
exceeding limit should be repaired or
replaced.
4. When enter the separator, 12-24 V
portable light should be used.
5. Before use the gas cutter or welder, lay
asbestos cloth at the inlet of the separator to
prevent sparks from entering the coal
pulverizer.
1.

2.
3.1 It should be free of
powder accumulation.
3.2 thickness of the
inner/outer cone and pipe
should be 2 mm;
thickness of the support of
the inner cone should be
3 mm.
3.3 internal parts of the
separator should be intact.
(III) maintenance and
adjusting of reflector
baffle
1. Check abrasion of the baffle; repair or
replace if the abrasion is over limit.
2. Calibrate baffle and adjust its turndown
ratio.
1. Baffle thickness should
be 2 mm.
2. Baffle should be agile;
turndown ratio should be
uniform.
(IV)seal up 1. After maintenance of separator, clean all
internal debris.
2. Clean the joint surface and apply 10 mm
asbestos cord as packing; evenly tighten
bolts.
2.1 bolts should be intact.
2.2 It should be tight.
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(V) maintenance
powder return pipe
1. Estimate any abrasion based on
operation; abrasion of the elbows should be
checked once a year. Repair or replace
parts with serious abrasion.
2. Check powder return pipe for any
pulverized coal blockage, accumulation or
leakage; correct if necessary.
3. Check outer insulation of the TPRI-SZ
series serial biaxial coarse Pulverized-coal
Separator.
4. After maintenance, air leakage test should
be carried out.
1. Thickness of pipe wall
should be 2 mm.

2. Powder return pipe
should be free of
blockage, accumulation
and leakage.
3. Insulation should be
complete.
4. It should be free of air
leakage.
(I) Main maintenance tools: adjustable spanner, ladder, safety belt, gas mask, protective
goggles, etc.
(II) Consumable and spare part spare parts:
Name Size Material Unit Quantity
1. Lower cone A3 Pcs 1
2. Reflector baffle A3 Pcs 32
3. Round steel 10 A3 M 15
4. Aluminum sheet 0.7MM A3 M2 6
5. Holding screw M1660 A3 M16 30
6.clamp nut M16 A3 M16 30
7.gasket 16 A3 16 30
8. White paste paint Barrel ?<0} 0.5
9. Asbestos cord M 10
In addition, to prepare: steel plate, steel pipe, etc..
4.3.3 Maintenance of woodblock separator
Woodblock separator installation is located on the outlet pipe of coal pulverizer, which is
used to separate the woodblock in the raw coal out of coal pulverizer. Its operating principle is
that: when woodblock is carried out by the pulverized coal air flow from coal pulverizer, it will be
stopped by the woodblock separator screen and absorbed to the screen. Pulling down the
screen will cause the woodblock to fall down on the grating; then recover screen and open the
rectangle hand hole to clean woodblock.
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Maintenance items, workmanship and quality standard of the woodblock separator
(I) preparation 1. Prepare maintenance tools and lighting
facilities.
2. After work sheet is issued, open rectangle
hand hole and maintenance door.
3. Clean woodblock and other debris from the
grating and screen.

(II) check abrasion
and action of the
internal and
external parts

1. Verify internal and external parts are intact;
complete the missing parts.
2. Check abrasion of the screen; repair or
replace if necessary.
3. Check abrasion of the casing and
diaphragm; repair or replace them if necessary.
4. Take out grating, check its abrasion.
5. Check agileness of the screen and baffle.
If seizing is found, remove bearing cap, clean
padding inside bearing housing; add padding
and recover it after adjust tightness.
1.
2. Thickness of the
frame band iron of the
screen should be 2
mm. Thickness of
grating and grid bar
should be 1 mm.
3. Casing thickness
should be 2 mm.
Thickness of diaphragm
should be 1 mm.
4. Thickness of grating
should be 1 mm.
5. Operation of screen
and baffle should be
agile.
(III) Close
maintenance door
1.when activities above said are completed,
close rectangle hand hole and maintenance
door
2. Joint surface should apply with asbestos
cord as padding; all bolts should be evenly
tightened.
2.1 should be free of air
leakage.
2.2 bolts should be
intact.
4.3.4 Maintenance of wood scraps separator
Wood scraps separator is located after fine pulverized-coal separator and air locker, which
is used to separate wood fibre from the pulverized coal.
Pulverized coal enter wood scraps separator from its lower part. Pulverized coal enters the
pulverized coal bunker after wood fibre is separated. Turn the screen turntable 180 and open
hand hole. Then wood scraps remained on the screen can be cleaned. This process will not
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affect the normal operation of the wood scraps separator.

Maintenance item, Workmanship and Quality standard for wood scraps separator
Maintenance
item
(I) Preparation
prior to
maintenance
1. Prepare maintenance tool and lighting
facilities.
2. Before work sheet is issued, no maintenance
is permitted.

(II) Screen
maintenance

1. Open right cover plate. Take out four
screens and clean wood scraps and other
debris.
2. Check sieve for any rupture and repair or
replace if necessary.
1. Screen mesh
should be free of wood
scraps and other
debris blockage.
2. Sieve mesh should
be intact.
(III) Maintenance
of turntable

1. Remove hand wheel and bearing gland
bush; add diesel before rotate shaft to make it
move agilely.
2. Recover bearing gland bush and hand wheel
1. Turn around hand
wheel and the rotation
should be agile.
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(before recover check felt sealing and
gasket, replace unqualified materials).

2. Tightness of the
gland bush should be
suitable.
(IV) recover cover
plate
1. Locate four screens. Recover right cover
plate and lay down felt before tighten bolts.
1. Bolts on cover plate
should be intact and
free of powder leakage.
4.3.5 Air locker maintenance
Air locker used in this project contains two types: cap type and flip/flop type. Cap type air
locker is used on straight pipes, which is composed of casing, conical cap shaft and heavy
hammer. Flip/flop type air locker is installed on the declining pipes. When turning plate is
closed, it should form a angle of 60 degree with the fuel flow direction. It is composed of casing,
turning plate, shaft and heavy hammer. Air locker is used to prevent air entering the system
when pulverized coal passes air lock to pulverized coal bunker (or when coarse powder drops
into coal pulverizer). Air lockers in system are in series with two units. When one unit is open,
the other is in close state.
Maintenance items, workmanship and quality standard of the air locker
Maintenance
item
(I) Preparation Prepare tools and lighting facilities.
(II) Check
abrasion of
internal parts

1. Remove upper and lower joint flange of the
air locker.
2. Check abrasion of the internal parts; repair
or replace parts seriously worn.

2.1 Abrasion of the valve
(or ball valve) should not
exceed 1/3 of the former
thickness.
2.2 Thickness of the air
locker casing should be
2 mm.
(III) Check
tightness and
agileness
1. Check tightness of valve (or ball valve).

2. Adjust the moving part of the air locker to
agile.
1. Valve (or ball valve)
should be closed tightly.
2. Air locker should
operate agilely without
blockage.
(IV) Adjust
balancing
hammer
Adjust balancing hammer as per
requirements.

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(V) Recover 1. Check bolts of parts.
2. Install air locker into the former system (seal
the joint surface with qualified asbestos yarn),
and tighten bolts.
1. Bolts should be
intact.
2. Air locker should be
tight without leakage.
4.3.6 Coal gate maintenance
Coal gate is located at the lower coal hopper which is used to isolate raw coal. Its operating
Principle is to open of close the coal path by inserted parallel pipe and it is easy for the
maintenance of coal feeder.
Coal gate Maintenance item, Workmanship and Quality standard
Maintenance
item
(I) check abrasion
of channel steel
frame
1. When raw coal bin is empty, check
abrasion of the channel steel; repair or
replace part if abrasion limit is exceeded.
1. Average thickness of
the frame should not be
less than 1/3 of its former
thickness.
( II) Check
abrasion and
operation of spile
1. Check abrasion of the spile and its
operation. Worn spile should be replaced;
spiles with visible bending should be
calibrated.
1. Spile should be free of
wornout and visible
bending. Its operation (in
and out) should be agile.
4.3.7 Explosion door maintenance
Explosion door is a device used to protect system and equipment. Explosion doors in
coal pulverizing system are normally installed at the outlet of coal pulverizer, outlet of
pulverized-coal exhauster and on the equipment of TPRI-SZ series serial biaxial coarse
Pulverized-coal Separator and pulverized coal bunker. Its operating Principle is that: when
explosion occurs in some part of the system, explosion door will burst at first to rapidly release
the pressure caused by explosion so as to protect the system and equipment from damage.
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Maintenance items, workmanship and quality standard of explosion door

Maintenanc
e item
Workmanship and precautions n Quality standard
(I)
Preparation
1. Decide whether to build scaffold
according to the position of the
explosion door; scaffold should be
checked by relative party before
application.
2. Prepare necessary tools and spare
parts.

(II) Check
explosion
door
1. Check explosion door for any rusting
wornout or leakage. Replace iron sheet
of the explosion door not satisfy
requirements. When replace, apply new
qualified packing seal and tighten bolts
evenly.
1.1 Diaphragm plate explosion doors
should be free of rupture.
Diaphragm plate must be made by
0.5 mm galvanized sheet iron.
1.2 Explosion door flange bolts
should be intact and its joint surface
should be tight.
4.4 Maintenance of Pulverized Fuel Feeder
4.4.1 Technical specifications of pulverized fuel feeder
(I) Equipment introduction:
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1 General
SGF series pulverized fuel feeder is fabricated by Shenyang Huadian Power Engineering
Company Limited based on absorbing advantages of all kinds of pulverized fuel feeders. It is
the latest developed product against current application conditions and problems of Chinese
pulverized fuel feeder. This equipment is characterized by its advanced principle, complete
function, compact structure and accurate output adjustment. It is suitable for pulverized coal
with fineness of R90=12%, moisture content (dry basis) of 1.3% and medium temperature of
120 . This device has high reliability and maintainability, which is highly regarded by clients.
1.1 Type description
SGF -XX

Capacity tones/ hours

Code for coal feeder

1.2 Operating Principle
SGF type pulverized fuel feeder is an advanced powder feeding equipment. Pulverized
coal flows to the baffle plate on the upper of pulverized fuel feeder and gullet of impeller through
coal bunker. Rotating impeller brings the pulverized coal to the powder falling outlet at the
bottom of impeller casing. Pulverized coal drops to the discharge impeller. After 90 turn, the
impeller transports the pulverized coal to powder discharge pipe via powder falling outlet. The
whole process is continuous, even and automatic. Powder flow is adjusted by changing the
speed of impeller.
1.3 Features of equipment structure and performance
The entire unit is composed of upper part, lower part and reducer.
Upper part assembly:
Upper part assembly adopts flashboard structure maximizing the space for coal feeding; it
eliminates the potential of pulverized coal bulking; thickness of the sealing layer is increased to
ensure the reliability and tightness of the sealing of the flashboard plate sealing. Stainless
steel flashboard plate has stronger capacity against environmental corrosion and other
pulverized coal corrosion.
Lower part assembly
Lower part assembly is the main part of the pulverized fuel feeder. Main shaft, scraper and
impeller form the conveying part for pulverized coal inside the lower part. Its structure can
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sufficiently ensure the operator to accurately control the output of the pulverized fuel feeder and
prevent pulverized coal from flowing automatically.
Reducer assembly
Reducer is composed of a stage of worm assembly. Flange of the reducer is connected
to the lower part of feeder via reducer seat. Reducer output shaft connecte with the main shaft
via a cross sliding block coupling. Reducer structure is compact easy for maintenance. And
reliable sealing ensure reducer free of seepage.
(II) Equipment specifications:
Type: series pulverized fuel feeder
Structure is shown below:

1.Flashboard 2.Upper part 3.Handwheel 4.Feeding impeller casing 5.Feeding impeller
6.Drive pin 7.Measurement impeller 8.Butter cup 9.Vent cock 10.Worm gear casing
11.Worm 12.Main shaft 13.Conical roller bearing 14.Worm wheel 15.Powder outlet pipe
16.Cap of the reducer 17.Lower part 18.Gland bush 19.Sealing unit 20.Clapboard
21.Scraper 22.Middle sleeve
4.4.2 Maintenance of impeller pulverized fuel feeder
(I) check before 1. Check current value, vibration 1. Current value should be 5
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maintenance value and bearing temperature of
the pulverized fuel feeder under
rated load,.
2. Review the defect record of the
equipment.
3. Check pulverized fuel
feeder for any oil leakage or
powder leakage.
4. Check pulverized fuel feeder
inside for any abnormal sound.
5. Verify the joint bolts of the
pulverized fuel feeder are intact
and tightened.
ampere; vibration value should be
0.1 mm; bearing temperature
should be 70 .
2. Defects should be accurately and
completely reviewed.
3. Should be free of leakage.
4. Should be free of abnormal
sound.
5. Bolts should be intact and well
tightened.
(II) disassemble
pulverized coal
chute, motor and
pulverized fuel
feeder
1. Verify pulverized coal bunker is
free of pulverized coal inside.
2. Close left and right flashboard
plates of the pulverized fuel
feeder; empty pulverized coal in
the coal feeder before shutdown.
3. Cut off power supply and
disconnect circuit breaker; carry
out a switching to verify the power
supply has been cut off before
maintenance.
4. Remove pulverized coal chute
flange bolt, and take off pulverized
coal chute.
5. Apply temporary end enclosure
at the primary air pipe inlet to
prevent debris.
6. Remove accumulated coal in
the pulverized fuel feeder.
7. Remove oil drain hole bolts,
and completely drain out lube oil
inside the pulverized fuel feeder.
Oil should be stored with special
bucket to avoid fire.
8. Remove coupling cage and

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coupling connecting screw to
dismount the motor.
9. Dismount pulverized fuel
feeder, and clean internal
pulverized coal.
(III)Dismantling of
scraper and
upper/lower
impellers
1. Disassemble top bolts, spring
gasket and spur guard to take off
scraper.
2. Remove diaphragm sunk screw
to take off lining plate and upper
feeding impeller; remove middle
lining plate to take out drive pin
and lower measure impeller;
disassemble middle sleeve on the
main shaft.
3. Before disassembling activities,
match marking should be made;
removed parts should be
numbered.
4.. Recover parts as the reverse
order of dismantling; measure
and adjust the following items:
(1) Measure scraper tortuosity,
radial clearance and clearance
between scraper and upper lining
plate filler gauge.
(2) Measure radial clearance
and upper / lower clearances of
the upper/lower impeller and
casing with filler gauge.
(3) Measure clearance between
main shaft and middle sleeve with
slide caliper and inside calipers.
1. Scraper should be free of crackle
and damage and its bottom should
be flat.
2.impeller,lining plate and sleeve
should be intact.
3.
4.1.1 scraper radial clearance
should be 1.5~5 mm.
4.1.2 Clearance between scraper
and upper lining plate should be
1.2~1.4 mm.
4.1.3scraper tortuosity should be
0.5 mm.
4.1.4 Spur guard and top bolts
should be complete and secured
with spring gasket.
4.1.5manually turning of scraper
should be agile.
4.2.1 Radial clearance of upper
/lower impellers and casing should
be 0.50.15 mm.
4.2.2 Upper clearance should be
1.2~2 mm.
4.2.3lower clearance should be
1-1.5 mm.
4.3 it should be 0.05~0.10 mm;
replace it when clearance > 0.20
mm.
(IV) dismantling
worm wheel reducer
1. Remove middle connecting
screw of the pulverized fuel
feeder; lift the worm wheel
3.1 Main shaft appearances should
be free of crackle, drawing stamp
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casing reducer casing and powder
exhaust pipe to a position laid
with woodblock. Before
disassembling, make match
marking on relative parts.
2. Disassemble gland bush of the
worm wheel reducer casing upper
cover, main shaft and middle
sleeve.
3. Wash, check and measure
main shaft.
4. Remove oil deflector ring,
worm, worm wheel, coupling and
bearing; wash and check them.
5. Recover worm and worm
wheel; adjust clearances between
parts; install coupling on the worm
shaft. Coat the shaft within oil
before assembling and install oil
deflector ring.
Sealing of felt at the joint of the
main shaft and worm wheel
reducer casing upper cover
should be good. End cover joint
surface should be coated with
shell-lac and replace a new
padding.
Fill new lube oil.
and burr.
3.2 Tortuosity and ellipticity of the
main shaft should be 0.5 and
0.05 mm respectively.
4.1 Bearing surface should be
smooth free of pocking mark,
crackle and other defects.
4.2 Clearance of bearing balls
should be 0.1 mm.
4.3 Worm bending should be
0.15 mm.
4.4 Steel bushing of the main
shaft bearing and bearing inner
hole of the worm wheel should be
homocentric; and
nonperpendicularity of the
working impeller surface should be
0.04/100.
4.5 Abrasion of the worm and worm
wheel tooth surface should be
1/2 of the former thickness.
5.1 Contact area of the
engagement of the worm wheel
and worm should be 60%.
5.2 When modulus is 5, root of
tooth clearance during engagement
of worm wheel and worm should be
1.25-1.50 mm.
5.3 Swaying clearance of the worm
should be 0.2 -0.25 mm.
5.4 Indication of oil level and clear.
5.5 Reducer casing should be free
of oil leakage.
(V) dismantling of
upper part
1. Remove upper part from the
pulverized fuel feeder; dismantle
and wash maintenance drive
screw mandrel and nut.
1.1thread abrasion should not
exceed 1/2 of former thickness.
1.2 swaying of screw mandrel
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2. Check and repair powder falling
flashboard and manhole.
3. Reinstall upper part onto the
lower part; replace gasket and
tighten bolts.
should be 0.02 mm.
1.3 screw mandrel bending should
be 1 mm.
1.4 moving of screw mandrel
should be agile.
2.1 powder falling flashboard and
manhole should be tight without
leakage.
2.2 turndown ratio indication of the
powder falling flashboard should be
correct.
3. Joint surface between upper part
and lower part should be tight
without leakage.
(VI) recover coal
exhaust pipe
1. Replace padding, recover coal
exhaust pipe and tighten bolts.
1. It should be tight.
(VII) motor
installation
1. Install coupling onto the motor
shaft; lift it up to pulverized fuel
feeder body; align axial and radial
clearance of motor coupling and
worm coupling.
1. Both axial and radial clearance
should be 0.05 mm.
(VIII)pulverized fuel
feeder test run
1. Check lube oil filling of parts.
2. Check tightening of the
connecting screws.
3. Close coal falling baffle.
4. Manually rotate coupling to
check its operation.
5. Protection device should be
kept intact and reliable.
6. During test run, increase rotate
speed gradually and record the
no-load operation of the
pulverized fuel feeder under
different rotate speeds. Time of
test run is 4 hours.
1. Oil quality is acceptable and oil
level is correct.
2. Joint bolt should be secure and
reliable.
3. It should be free of seizing
and abnormal sound.
4. It should be free of oil leakage,
powder leakage.
5. current, vibrations, bearing
temperature should be in the
specified range.

Maintenance main tools and spare parts of impeller pulverized fuel feeder
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(I) Main maintenance tools:
Wrench, hoist, tommy bar, hand hammer, copper bar, screw driver, wire cable, scraper,
abrasive paper, filler gauge and gear puller.
(II) Spare parts
Common faults and trouble shooting for impeller pulverized fuel feeder
Faults Cause Treatment
(I) large
current

1. Clearance between main shaft and
middle sleeve is too large and sealing is
poor; pulverized coal enters sleeve;
lubrication is bad.
2. Clearances of sealing positions exceed
limit; pulverized coal enters reducer
casing, lube oil deteriorates; friction of the
worm wheel and worm increases.
3. Clearance between impeller and
diaphragm is too small causing abrasion.
4. Impeller surface is not vertical to shaft
causing abrasion.
5. Worm is free of swaying clearance or
too low clearance.
6. No axial play clearance between two
couplings.
1.1 wash and replace gland packing
as well as improve lubrication.
1.2 repair or replace middle sleeve.
2. Improve sealing.
3. Replace gasket and adjust
swaying clearance.
4. Redisassemble it and adjust
verticality; replace damaged parts.
5. Adjust the clearance with gasket
until a proper value.
6. Adjust the clearance to a suitable
range.
(II) oil
leakage
1. Sealing is invalid or synthetic glass of
the oil level gauge is damaged.
1. Replace sealing or oil level gauge
synthetic glass.
(III) motor
vibration
1. Coupling center disposition.
2. Motor set screw loose.
1. Align center again.
2. Tighten set screw.
(IV) oil
quality
deterioration
1. Quality of former lube oil is
unacceptable or pulverized coal enters
oil.
1. Replace new oil; eliminate
powder leakage and replace oil seal.
(V)pin of
scraper
breaks
1. Strength decreases because of
abrasion.
2. Woodblock, iron block or other foreign
matters block to cause overload.
1. Replace pin.
2. Remove debris.
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4.5 Pulverized Coal Conveyer Maintenance
4.5.1 Pulverized coal conveyer technical specifications
(I) Equipment introduction
Conveyor is transporting equipment mainly used to evenly distribute pulverized coal from
fine pulverized-coal separator to individual pulverized coal bunkers.
Type: LSG-500 transmission distance: 32.2m. Capacity: 100t/h; motor power:
27.5KW

General installation of equipment
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Sectional view of the box
4.5.2 Maintenance items of the pulverized coal conveyer
(I) preparation

1. Prepare maintenance tools and lighting tools.
2. Issue work sheet thermodynamic
maintenance and verify all safety provisions
have been ready before maintenance.
3. Empty pulverized coal inside packing auger
before start maintenance.

(II) reducer
maintenance

1. Disassemble coupling and reducer as well as
bottom plate joint bolt. Lift reducer with hoist on
the maintenance support.
2. When disassemble parts, match marking
should be well made.
3. Disassemble small end cover and frame joint
bolt, open casing cover.
4. Disassemble frame and gear roller joint bolt,
remove frame .
5. Turn four screws into the screw hole of the
load balancing ring. Evenly separate load
balancing ring from the pin roll; then take out pin
roll bush.
6. Lift out pin wheel housing and knock the tooth
1. Frame should be intact
free of crackle and oil
leakage.
2. Pin roll and pin bush
should be free of bending
deformation; abrasion
should be 0.05mm.
3. Eccentric shaft
eccentricity should be
20.02 mm; bearing should
be tightened.
4. Keyway abrasion should
be 1mm, inner outer ring
of bearing and rolling parts
should be free of crackle,
corrosion; rotation should be
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pin with copper bar to remove gear roller.
7. Take out upper cycloidal gear diaphragm and
lower cycloidal gear.
8. Take out eccentric shaft assembly.
9. Disassemble input shaft positioning bolt, take
out large end cover and oil seal.
10. Wash all parts.
11. Check frame, input shaft, output shaft, pin
roll, pin bush and eccentric shaft abrasion.
12. Check bearings appearance and measure
clearance.
13. Check abrasion of cycloidal gear and cam.
14. Check abrasion of the pin wheel housing,
gear pin and gear roller.
15. Based on match marking recover reducer
and fill in qualified lube oil.
agile; bearing clearance
should be 0.15mm.
5. Cycloidal gear and cam
should be free of crackle,
abrasion should be
0.1mm.
6. Pin wheel housing should
be intact without crackle or
oil leakage. Gear pin, gear
roller should be free of
bending deformation,
abrasion should be 0.1mm.
7. Oil seal should be
properly installed.
8. Rotation should be agile
without seizing.
9. During test run, vibration
should not exceed limit and
free of oil leakage and other
abnormal situation.
(III) chain wheel
maintenance

1. Check parts of chain wheel, any crackle
should be repaired immediately.
2. Check inspection doors, supporting roller,
fairlead wheel, scraper plate and inlet, outlet
flashboard. Replace the part with defects unable
to be repaired. Verify the wire cable is intact.
3. Check joint surface bolts.

1. Chain wheel should be
intact, and parts should be
free of crackle.
1.1 check doors should be
intact, and sealing is
acceptable.
1.2 Supporting roller, gear
blocks, fairlead wheel,
scraper rod fixture block
should be intact without
deformation, rupture and
digression.
1.3 When the abrasion of
inlet/ outlet flashboard is
greater than 1/2 of former
thickness, replace the part.
Sealing should be tight with
a clearance 0.20mm.
Otherwise add gland
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packing.
1.4 wire cables are free of
breaking; joint should be
secure.
2.1 bolts of parts should be
intact without damage.
(IV) installation of flight
chain
1. Flight chain is the key part of the embedded scraper transporter. Before
installation, verify joints of flight chain are agile. Remove if necessary. Grind
pin roll and chain bar hole with abrasive paper. Do not coat lube oil or grease.
2. Before installed in flight chain, head and tail cover plates should be
checked and sight cap be open. Move the tail shaft to the foremost front of
the head direction to determine the direction of the flight chain (refer to Fig3)
and prepare flight chains needed and the others are to be used as spare
parts.
Great wheel teeth drive the large head of the chain bar of the flight chain;
and direction should be proper. The following figure shows the
engagement of the great wheel teeth and flight chain when great wheel runs
as per direction shown in the figure.
Flight chain installation diagram
Chinese English
Cable wire
Head
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Changeover portion
Middle section
3. Before installation of head part, prepare two wire cables which is 3-4m
longer than the length of machine body. Then install transition section. Pull out
upper and lower cable wire towards tail direction. Install middle section, and
tail section orderly. After installation of the main equipment, the upper and
lower wires should have been pulled to the tail part.
4. Firstly install lower flight chain; tight the first group of flight chain ( ten
sections as on group) with cable wire at the tail part; pull the lower cable wire
to pull in the first group of scraper and then connect it with another group.
Keep drawing the lower wire until the lower wire is pulled out from the head
section.
5. Then install upper flight chain in the same way of installation of lower flight
chain. However, their direction is opposite. If the head rotates
counterclockwise, the small head of flight chain will move towards the head
direction and the large while that of the upper flight chain is opposite.
6. Connection of the flight chain. First connect the upper and lower flight
chains at the head section. Then pull the upper or lower flight chain at the tail
section. Tension flight chain to define a suitable length and then connect the
flight chain at the tail part. Installation of main machine and flight chain
complete.

Running direction
Large head
7. Precautions
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A. Installation of the flight chain must be correct with the same direction as
great wheel.
B. Clamp the elastic collar or weld the pin roll retaining rings when connects
the flight chains. Otherwise, during flight chain operation, pin roll may loose
or cause serious accident.
(V) installation of drive
device
1. Motor reducer and drive mechanism should be securely welded on the
foundation platform or head of the main machine. Details please refer to
[Technical Agreement] and [Contract]. During installation, the output shaft of
the reducer should be parallel with that of great wheel. During open chain
driving, the centerlines of the great and small chain wheels should be on the
same straight line. The following check method could be adopted. After
adjustment of the drive device, weld it with the foundation securely or secure it
with bolts to ensure stable operation of the equipment.

Check method of drive device installation quality
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(VI)preparation before
test run
1. After installation of parts, carry out no-load test. The following procedures
should be done for no-load test preparation:
1.1 all bearing driving chains and reducer should contain sufficient lube oil
and grease.
1.2 check machine groove for any left tool and material; remove if any.
1.3 primarily check tightness of chain by the following ways:
First throw the coupling between motor and reducer or pull straight the chain
below motor fan blade, and then check the loosing position of the great wheel
( shown in the Figure)
Check method for chain jamming tension

(V) test run

1. Motor test runs without load test and verify the
rotation direction; tighten coupling bolts and
recover casing before 1 hour no-load test run;
check for any abnormal situation.
2. On-load test run for 1 hour.
1.1. It should be free of oil
leakage, powder leakage;
there should be no abnormal
sound from individual parts.
2.2. Current, vibration and
bearing temperature should
be in the specified range
(I17A, vibration 0.10mm,
bearing temperature 40 ).

4.5.3 Pulverized coal conveyer trouble shooting
Faults Cause Treatment
Flight chain run out 1. Installation of the conveyer is not
good
1. Check installation quality
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(1) straightness of whole machine is
over limit
(2)head and tail block are not centered
(3) wheel axle deflexion
2. Casing may deform 2. Calibrate casing
3.tailblock adjusting strokes are not
uniform; tail block deflexion
3. Adjust evenly
1. Hard objects in the machine groove
block the chain
1. Remove debris
2. Chain abrasion is serious 2. Replace chain
3. Full load startup or sudden load
increasing
3.feed materials evenly after
manually material discharge
Flight chain is
broken
4. Collar on the chain falls down to loose
pin roll out
4. Spot welding of collar
1. Casing is not straight; flange and
lead rail are dispositional
1. Readjust
2, hard objects in the machine groove 2. Remove debris
3. Scraper and chain bar are not well
welded.
3. Replace chain link
Deformation or
rupture of scraper
4. Engagement of the flight chain and
great wheel is not good.
4. Check adjust
1. Hard objects or iron parts in the
machine groove
1. Remove debris Flight chain impulse
with sound during
operation
2. Rotation of a certain chain link is not
agile
2.remove pin roll to repair
1.great wheel shaft deflexion 1. Calibrate and adjust the
shaft level
2.great wheel is uncentered 2. Calibrate great wheel
Engagement of the
great wheel and
flight chain is not
good
3. Chain space increases after long term
operation
3. Replace chain
Floating chain 1. Chain tensionness is not enough 1. Adjust tensioning device
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2. Material form a pressed layer on the
casing bottom plate
2. Clean and add pressing
rail if necessary
4.5.4 Operation and repair
1. After each startup, run without load for awhile until equipment operates normally before
feed materials. Feeding should be kept evenly without sudden change or overload.
2. Unless specified, equipment should not be shutdown with load. Normally, equipment
should not be shutdown until materials in the machine groove are discharged. For the
startup after emergency shutdown because of full load transportation, Jog the equipment
for several times or manually remove the material in the machine groove.
3. If several conveyors form a streamline, the last one should be started up at first while the
shutdown procedure is opposite. The startup also can be control by interlocking
4. Operator should regularly check parts of the machine. Especially the flight chain and drive
device should be kept intact. Immediately repair or replace the damaged parts (such as
deformation of scraper, falling off of the cotter pin, serious abrasion of the bending section
of the lead rail).
5. During operation, prevent iron part, large hard objects or debris from entering conveyor to
avoid equipment damage or accident.
6. Keep good lubrication of all bearings and drive parts. Lubrication of embedded scraper
transporter is shown in the following figure. Attention should be paid not to apply grease on
the flight chain, support lead rail and great wheel, tail block.
7. Normally a minor overhaul every 6 months, a medium overhaul every year and an overhaul
every 3 years should be carried out for the embedded scraper transporter. During
overhaul, all parts of the embedded scraper transporter should be removed and cleaned;
replace abrasion parts. Motor, reducer should be maintained or repaired as per their
relative technical requirements.
8. For conveyor operating seasonally, maintain and care it during outage. A little #10 lube oil
can be dropped between flight chain pin roll and chain bar to avoid seizing caused by
corrosion; food oil can be used in case of foodstuffs delivery.
Lubrication part Lubrication material Lubrication
interval
Lubrication method
Turning bearing 1#lithium base grease 500 hours Oil gun or coat
Lead rail of tensioning
device
1#lithium base grease 800 hours Coat
Adjusting screw of
tensioning device
1#lithium base grease 800 hours Coat
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Exposed driving chain Exposed gear
oil(220#)
1.5 months Coat
Gear reducer N320 gear oil Every 3 months
after 1 month
Fill
Motor 1#lithium base grease 3 months Coat
Appendix 2 main wearing parts breakdown table

5 Tailblock Aperture D=110
4 Great wheel Aperture D=160 Tooth number Z=9
3 Outlet flange
2 Pin roll
1 Flight chain Include pin roll and collar, etc.
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Serial No. Name Drawing No. Remarks
4.6 Jet Lubrication Unit Maintenance
4.6.1 Jet Lubrication Unit Technical Specifications
(I) Equipment Introduction:
Coal pulverizer jet lubrication unit is the lubrication equipment for coal pulverizer large gear
tooth surface, mainly composed of oil system, air system, control system and sprinkler plate; its
operating Principle is to atomize the high viscosity lube oil by compressed air via a specially
designed jet valve and jet the oil onto gear working face. Form and maintain a layer of oil film on
the surface of the gear engagement to realize liquid friction.
Fig. 5-6-1 Diagram of coal pulverizer jet lubrication system
Chinese English
Oil system
Air system
Sprinkler plate
Large gear
Small gear
Gear cover
(II) Main technical parameters:
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Working medium: industry gear lube oil N460;
System oil pressure: 0.05-1.2MP
System air pressure: 0.05-0.7MP
Lubrication width: 270-800mm
Jet distance: 200+10mm
Oil supply capacity: 3.15L/min
Volume: 120L
Main circuit parameter: 380 V 1.5A
Air pump parameter: 220V 9A (4.5A)
Control circuit parameter: 220V +5% 50Hz
Dimension: 10005001600mm (double-machine: 1730mm)
4.6.2 Jet Lubrication Unit Maintenance
(I) maintenance of
oil line system of
coal pulverizer jet
lubrication unit
1. Pump out residual oil inside oil
tan.
2. Disassemble oil pipe and open
oil tank upper cover.
3. Remove joint bolt of the oil
pump and remove entire oil
pump to check.
4. Clean debris dirt inside oil tank
and oil pipe, and blow oil tank,
check oil pipe and joint for any
blockage and seepage .

3.1. Check from the appearance of
pump body, coupling should be
free of defect.
3.2. Pump should be free of
abnormal sound during operation;
gear engagement should be
stable; joint flange of end cover
and casing should be tight.
4. Oil tank, oil pipe should be free
of debris, dirt, oil pipe and joint
should be free of blockage and oil
leakage.
(II) coal pulverizer
jet lubrication unit
air system
maintenance
1. Vent residual air in the air
compressor; remove air
compressor air pipeline and
check relative valves.
2. Remove complete air
compressor from the housing;
1. Air pipeline, air compressor
head gasket and pressure
regulating valve, check valve
should be intact without air
leakage.
2. Air compressor should be free of
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check air compressor and air
compressor proper.
oil leakage and air leakage with
proper pressure.
(III) maintenance
of sprinkler plate oil
injection nozzle of
the coal pulverizer
jet lubrication unit
1, disassemble oil pipe and air
pipeline connecting sprinkler
plate 2, dismount oil injection
nozzle from sprinkler plate,3,
check and clean sprinkler plate,
oil injection nozzle and pipeline.
1. Sprinkler plate should be intact;
oil injection nozzle and pipeline
should be intact without blockage.
4.7 Maintenance of primary air pipe
Maintenance
item
(I) check inside of
primary air pipe
1. Open a hole of 300mm at the
elbow of primary air pipe to check
abrasion of air duct.
2 check primary air pipe inside for any
1. Inside should be free of obvious
abrasion; abrasion of hexsteel
should not exceed 2/3 of the former
thickness.
2. Verify air duct inside is free of
Hot air system
Maintenance
item
(I) Check isolating
valve
1. Open bearing housing of the hot air
valve, take out gland bush, and check
packing set.
2. Check connection of the isolating
valve flashboard and cylinder shaft for
any sealing off and bolt loosing.
3. Check agileness of the flashboard.
1. Packing set is intact, without
damage or ash leakage.
2. Bolt is free of loose and sealing
off.
3. It closes and opens agilely without
seizing.
(II) Adjusting
valve
1. Open bearing housing of the
adjusting valve and take out gland
bush to check packing set.
2. Check connection of the isolating
valve flashboard and cylinder shaft for
any sealingoff or bolt loosing.
3. Check agileness of the flashboard.
1. Packing set should be intact
without are leakage.
2. Bolt is free of loose and sealingoff.
3. It closes and opens agilely without
seizing.
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(III) hot air pipe 1. Check hot air pipe for any ash
leakage.
1. Sealing is tight without air leakage
or ash leakage.
4.8 Maintenance of Bag-type Dust Collector
Maintenance
item
1. Cut off the motor power supply of
lower spiral conveyor of the dust
catcher.
Before maintenance, make sure
motor power is shut down.
(I) Maintenance
preparation
2. Close outlet cinder valve of the
dust catcher.

1. Open upper cover plate of
collector.

2. Check primary port. Primary port is clean without
blockage.
3. Clean the bags inside the bag-type
dust collector.
Bag is clean inside, pressure
deference is normal during test run.
(II) Maintenance
of the upper and
lower box
4. Check the frame. Thickness of the internal frame
should not be less than 1/3 of the
former thickness.
(III) maintenance
of ash handling
system
1. Check mesh of blowpipe for any
blockage.
Mesh of the blowpipe should be
free of blockage.
(IV) maintenance
of spiral
pulverized coal
conveyer
Refer to the spiral pulverized coal
conveyer at the lower part of the
powder separator

1. Maintenance of the reducer refer to
that of the above said cycloidal-pin
wheel reducer

2. Maintenance of separation gear. Thickness of the separation gear
should not be less than 1/3 of the
former thickness.
(V) maintenance
of cinder valve
(Variable
frequency feeder)
3. Pipe abrasion. Thickness of pipe wall should not
be less than 1/3 of the former
thickness.
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5 Primary air fan (mill fan), force draft fan , induced draft fan
5.1 Primary air fan (mill fan)
5.1.1 Technical specifications of primary air fan
Denomination of fan type and design parameter
Fan type: 1788AB/940
It means:
178=
impellerID
bladeOD

Blade OD: diameter of blade outlet
;
Diameter ID
:
diameter of impeller inlet
8-- Serial number of aerodynamic model
A-- Axial cutting of impeller
BDouble base
Diameter of impleer inlet (mm)
Technical specifications
TB BMCR
Medium: air air
Density: 112 kg/ m
3
1.168 kg/ m
3

Flow rate: 33.99 m
3
/s 25.89 m
3
/s
Total pressure:14850 Pa 11000 Pa
Inlet temperature:39 24
Rotate speed:1480r/min 1480r/min
Shaft power:347.3KW 259KW
Motor power:400KW
Angle: inlet: 90o outlet :0o(seen from the motor side)
Manufacturer: Shanghai Blower Works
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SFY15F-C5A General Assembly Drawing of Primary Air Fan
5.1.2 Maintenance of primary air fan
(1) Coupling
maintenance
1.Remove the coupling guard and the joint bolt,
clean up the removed parts and keep them in
order; marks used for reassembly and
alignment shall be well established.
2. Check the clearance among each part of the
coupling and record properly.
3. Check whether such defects as cracks and
deformation exist in the coupling.
4. Check whether the joint bolt is in good
condition. Whether bending deflection exists in
the bolt, non-conformity bolts shall be replaced.
Check whether the diaphragm is of intactness,
and exists no permanent deformation and
1. The coupling shall be of
intactness and keep
surface finish; with no
cracks and deformation;
the coupling and the shaft
shall be securely engaged
and without loose fits.
2.There shall exist no
bending deformation in the
joint bolt, the screw thread
shall be in good condition;
wahser, spring pad and
nut shall be furnished well.
3. The diaphragm and the
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cracks.
6. Assembly:
(1) After the center getting aligned, assembly
the coupling and clean up the coupling, pipe
nipple, diaphragm and joint bolt, etc.
(2) Align the pipe nipple with the original marks
of the coupling
(3) Refit the coupling guard.
Note: Contact shall be avoided between the
coupling guard and the ratating parts.
joint bolt shall be fitted
tightly and the clearance
shall not be over 0.30mm.
4. Lopsided wears of the
coupling and pipe nipple
are not more than 0.5mm.
5. Parts with a wear value
of more than 0.5mm shall
be replaced.
(2) Maintenance
of impeller and
current collector
1. Remove the housing and the bolts in the gas
inlet casing, and keep them properly.
2. Open the manhole door for apprasial prior to
maintenance and make records. Assembling
condition of the impeller shall be checked before
removing the impeller. 3. Check whether huge
deformation and cracks exist in the blade and the
impeller disk. 4. Repair welding shall be
performed if cracks and wear occur to the weld
joint between the impeller and the impeller
disk.Cracks shall be cleaned up prior to
performing repair welding.
5. Check whether the rivet and the bolt that
connect wheel hub and impeller disk get loosen
or worn.
6. Check the fit between wheel hub and the
main shaft to be free from loosen.
7. Check the current collector to be free from
deformation, correction shall be performed if a
set value is exceeded.
8. Check whether rub contact traces exist in the
dynamic and static parts.
1. The blade and impeller
disk shall be free from
cracks and deformation,
and the wear value of the
blade shall less than the
1/3 of the original
thickness.2. The joint bolt
and rivet that connect the
wheel hub and the
impeller disk shall be free
from loosen.
3. The fit between wheel
hub and the main shaft
shall be free from loosen,
and the tension force is
generally set at 0-0.02mm
4. Cracking phenomena of
the current collector shall
be refrained.
5. Refer to figure 5-1 for
the fit clearance between
the current collector and
the impeller.
(3) Check of the
inlet muffler

1. Check carefully from the inlet and outlet
sides of the muffler whether the mesh
enclosure of the muffler insulation plate is
corroded, whether the screw and mesh
1. Muffler insulation plate
shall be flat and level, and
be free from detachness,
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enclosure is detached or get tilted. If the mesh
enclosure is found corroded, tilted or
detached, repairation measures shall be taken
immediately.
2. Check whether the acoustic material in the
muffler insulation plate is exposured or
leaked.To prevent the acoustic material from
blocking the air passage and thus impairing
the power of the fan, treatment measures shall
be taken immediately if exposure and leakage
are found to be existed.
tilt and corrosion.
2. Acoustic material shall
be in good condition and
free from exposure.
4) Maintenance of
the main shaft

l. Check whether the main shaft is cracked,
corroded and worn.
2. Check the main shaft to be free from
bending.
3. Check the roundness size of the main shaft
journal and whether galling phenomenon
exists.
4. Check whether the protective sleeve of the
main shaft is in good condition.

1. The main shaft is free
from cracks, corrosion
and wear.
2. The bending
percentage of the main
shaft shall not be more
than 0.05mm/m and no
bigger than 0.10mm/m
over the full length.
3. The deviation of the
roundness size of the
main shaft journal shall
not be more than
0.02mm.4. The protective
sleeve of the main shaft
shall be in good condition;
the clearance between the
main shaft and the
protective sleeve shall be
0.06~0.08mm.
5) Maintenance of
bearing box and
bearing

1.Check whether the lube oil is deteriorated or
contaminated by sampling tests. When the
quality of the lube oil is unqualified, it shall be
changed.
2. Check the bolts in the upper and end
covers, the screw shall be free from cracks
and bending; the thread shall be intact and
fittings be complete; the removed bolts shall
1. The internal and
external sleeves of the
rolling bearing and the ball
bearing shall be free from
such defects as cracks,
obvious spots and corrode
pittings.
the bearing and the shaft
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be cleaned up and kept in order.
3. Measure the fit clearance among each part
of the bearing box and complete the records.
4. Clean up the bearing box; check the internal
and external sleeves, spacing ring and ball
bearing.
5. Measure the bearing clearance and spacing
ring clearance, and unqualified ones shall be
replaced.
6. Check and clean oil level gauge, oil level
gauge calibration shall be practiced if
necessary, the highest oil level is rarely higher
than the center line of the downmost ball
bearing of the bearing, and the lowest oil level
is rarely lower than 1/4 of the diameter of the
downmost ball bearing.
7. Check and clean cooling water pipes and
the cooler. When the scale buildup of the
cooling water pipes and the cooler have
seriously weakened the cooling effect, acid
cleaning shall be practiced, and the
concentration of hydrochloric acid solution
used shall be 5%-10%, and then rinse in clean
water.
fit shall be 0.02~0.04mm
the bearing and the
bearing box shall be
0.03~0.05mm.
4. The radial clearance of
the bearing shall be
0.11~0.18mm.
5. The oil level gauge
shall remain unclogged
and clear in vision.
6. The cooling water shall
be free-flowing with
proper amount of water,
and the valves shall be of
flexible operation.
(6) Maintenance
of the housing

1. Check whether the housing is of strong
fixation, whether exists the phenomena of
desoldering, corrosion and etch off.
2. Check whether the housing and supports
exist fatigue crack problem, if any cracks are
found, repair welding shall be carried out in
time; analyze the reasons and take
corresponding countermeasures..
3. Check whether the manhole and shaft seal
are in good order, the manhole shall shut
closely and there exists no friction between the
shaft seal and the main shaft.
1. Cracks are not allowed
to exist in the housing;
fixation shall be secured.
2. Tack weld shall be
refrained between the
housing and the supports.
3. Every weld joint is in
good order and the
welding shall be secured.
4. The sealing clearance
between the shaft and the
housing is generally
2~3mm, contact between
the felt of shaft seal and
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the shaft shall be uniform,
appropriate in tightness
and tight in leak proof.
(7) Rotor
reassembly
1. Bearing seat and external sleeve of the
bearing shall be cleaned up prior to rotor
reassembly, the rotor shall be carefully
handed during the process of reassembling to
prevent the occurance of equipment damage.
2.The alignment of the main shaft can be
performed through adding washer under the
bearing seat. The external sleeve of the
bearing and the bearing cover shall be
cleaned up prior to getting the bearing cover
back in position, the clearance between the
bearing cover and the topside of the external
sleeve of the bearing shall be measured
accurately with the method of Pressing Lead
Wire generally.Perform the measurement
twice and the difference between the two
measurement results shall not significant.
Determine whether it is necessary to add
washer or not in the joint surfaces of the
bearing seat and the topside of the sleeve
according to the measurement results in order
to have the clearance between the external
sleeve and the bearing cover complied with
the standard.
The lateral error shall not
exceed 0.1mm/m after
the alignment of the main
shaft; the washer number
usually is not more than 3
2. The contact angle
between the external
sleeve of the bearing and
the bearing seat shall be
90-120; clearance on
both sides shall be 0.14-
0.20 mm. Examination
of the contact surface
between the external
sleeve and the bearing
seat shall be practiced if
the bearing seat needs
being replaced.
3. Clearance between
the external sleeve of the
bearing and the bearing
cover: clearance of the
coupling side:
0.00-0.06mm; clearance
of the impeller side:
0.05-0.10mm.
4. The joint surface of the
bearing seat and the
bearing cover shall
remain clean and well
connected, and a
0.03mm thick feeler
gauge cannot be
inserted.
5. The radial clearance
between the end cover
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and the shaft is not more
than 0.10mm; packing
seal shall remain good
condition..
6.Thrust clearance shall
be 0.08-0.12mm.
8) Damper
regulator
maintenance
1. Check whether the switch of the damper
regulators are flexible, whether the actual
turndown ratio consistent with the indication.
2. Check whether damage such as cracks
exists in the shaft of the damper, replacement
shall be performed if any cracks exist.
3. Check the degree of wear of the damper,
and perform replacement if a set value is
exceeded.
4. Check whether distortion and wear case
exist in the damper, replacement shall be
performed if the damper is of gross distortion.
5. Check whether cracks exist in the damper,
whether the transmission device is in good
order.
6. Check whether distortion exists in the
damper regulator and regulating ring.
1. The switch of the
damper regulator shall be
flexible, and the indicaion
shall be consistent with
the actual turndown ratio.
2. Damper regulator shaft
shall be free from cracks.
3. If the shaft of the
damper has been worn
away more than 1/3 of
the original diameter,
replacement shall be
performed.
4. If the damper has been
worn away more than 1/3
of the original diameter,
replacement shall be
performed.
5.If any cracks exist in
the steel damper, repair
welding shall be
performed; transmission
device of the damper
shall be in good condition
and be free from
unsmooth stagnation.
(9) Preliminary
operation of the
fan
1. Clean up the gas duct that connects to the
housing prior to closing the manhole, and
hermetic performance should be assured
2. Check whether the cooling water is
free-flowing and keeps sufficient flow rate,
check whether the oil temperature and oil
1.Preliminary operation
time of the fan is 4-8h.
2. The axial and
horizontal vibration of the
bearing shall be
0.08mm during the
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level are normal.
3. Check the inlet guide damper regulator to
make it in closed position.
4. Familiarize with the position and function of
the buttons that switch off the power in situ.
5. Get ready the relevant measurement
instrument and apparatus.
6. Prior to switching on the fan for perliminary
operation, startup conditions shall be
confirmed by maintenance controller and
operators.
7. Measure the vibration condition of the
bearing after the fan starting and running
properly If vibration exceeds a set value,
analyze the reasones or perform dynamic
balance test.
8. Apart from measuring the vibration value,
the bearing temperature and the current
values when the air throttle is in various
turndown ratio still need to be recorded
regularly during the overall preliminary
operation process; check whether such
abnormalities as friction, oil leak, water
leakage and air leak exist.
preliminary operation.
3. Bearing temperature
is less than 75 .
4. The fan runs properly,
without abnormal noise
from running.
5. The damper switch
shall be flexible and
correct in indication.
6. All of the seals shall be
oil-proof, watertight and
airtight.

Attachment:SFY15F-C5A Performance Curve of the Fan
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0 15 30 45 60 Q(m3/s)
0
1300
2600
3900
5200
6500
P(Pa)
p=.797kg/m3 n=1490r/min

5.2 Force draft fan
5.2.1 Technical specifications force draft fan
1.1 General information
Fan type FAF20.4-10-1
Project number 2007-19
Year of build 2007
Name Vietnam Quang Ninh First-stage 2X300MW Thermal Power-generation Units
Project
Installation site Quang Ninh Power Plant
Air volume (m
3
/s) 177.60 (T.B) 140.80(BMCR)
Total pressure rise of the fan (Pa) 5267(T.B) 3660(BMCR)
Inlet medium temperature( ) 39.00(T.B) (BMCR)
Inlet medium density (kg/m
3
) 1.1120(T.B) 1.1680(BMCR)
Fan efficiency (%) 80.91 (T.B) 86.15 (BMCR)
Fan power (kw) 1135 (T.B) 605(BMCR)
Fan rotate speed (r/min) 1470
Motor power (kw) 1250
Motor rotate speed (r/min) 1482
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1.2 Mechanical parameters
Fan inside diameter 2040
Impeller diameter 1000
Impeller series 1
Blade model 16NA16
Blade number 16
Blade material HF-1
Connection of blade and blade handle Bolt
Bore and stroke of hydraulic cylinder 336/H50MET
Blade regulating range 45
o

1.3 Fan starting torque
Fan rotate speed n = 1470 r/min
Flywheel torque J = 0.25GD
2
= 7373kgm
2

Fan shaft power (under max. working condition) 1135Kw
Fan torque (under max. working condition) 7373Nm
Radial force of the motor shaft end F
R
= 2698 N
Axial force of the motor shaft end F
A
= 3000 N
Motor power Ne = 1250 kw
Being seen from the motor shaft end, the motor rotates clockwise, and the fan rotates
anticlockwise.
1.4 Major Parts Diagram of the Fan
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Chinese English

Fan torque

Fan rotate speed

Full open of blade
Full close of blade
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5.2.2 Technical specifications of force draft fan oil station
Fuel supply quantity: 25L/minworking pressure of hydraulic fluid: 3.0MPa working
pressure of lube oil: 0.30.6 Mpa; oli tank capacity: 0.25m
3
.
5.2.3 Maintenance of force draft fan and hydraulic fluid station
(1) Working
condition analysis
prior to
maintenance

Record the following values prior to maintenance
1. Vibration values of the fan and the motor.
2. Motor no load current .
3.Fan outlet air pressure.
4. Bearing temperature.
5. Leakproofness of the fan housing, remarkable
symbols shall be made out in leakage points.
Normal
temperature60 ~70
.
(2) Disassembly
of the upper part
of the fan.
1. Disassemble shround, horizontal flange of the
casing and the sound insulation layer of hoisting
rings.
The shround shall be
tight and complete,
with no cracks and
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2. Disassemble the shround of inlet air and primary
air and protection device.
3. Jack up the upper part of the fan casing by virtue
of the upper cover jackscrew of the fan, and put the
blade in off position. Hoisting and maintaining
upper part of the casing in the air, suspension height
shall be suitable for moving the casing without
touching the blade.With that, remove out
horizontally and put on the sleepers.
breaches; the rivets
bear no bending
deflection and
elongation
problem.Sealing ring
and spacer are free
from aging and cracks.
Joint bolt and dowel
pin shall be free from
bending deflection and
elongation problem.
3)Rotor
disassembly

1.Remove regulating shaft and indication shaft from
blade regulating device.
2. Detach the pipeline of main bearing box from the
main bearing box.
3.Detach the secure flat steel that prevents
hydraulic control head from reversing from hydraulic
control head of the hydraulic regulating device.
4.Remove thermometer for bearing off the bearing
box, loose the joint bolts that connect half coupling
of fan side and intermediate shaft.
5.Hold up the intermediate shaft from the inside of
gas inlet box, and maintain it straight and level to the
greatest extent to prevent damaging diaphragm
coupling.
6. Largest compression value of the diaphragm at
the motor side is 4 mm.
7. Loose the joint bolt that connects flange of main
bearing box and upper support ring of lower part of
fan casing.
8.Lift the rotor.
Note: the rotor shall be maintained horizontal and
balance in order to prevent blade from damage, lift it
out in the vertical direction from the lower part of the
casing, while ensure the dynamic being in off state.
9.Place the rotor on special support as that of
placing impeller in the casing and blade is not

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allowed to touch ground or chassis
(4) Disassembly of
blade handle
bearing
The dismantled parts sunch as blade, major blade
handle and bearing shall be numbered on the basis of
hole number of blade handle (such as blade handle,
balancer, blade handle bolt and Regulating bar)
before being put in a certain place, and the number is
not allowed to be deranged during installation again.

(5) Assembly of
blade handle
Clean, maintenance and parts changing (if
necessary) shall be performed in according to blade
handle bearing assembly drawing.
Working face treatment:
Examine leakproofness of blade handle bearing with
the method of pressure process.
Pressurize all of the blade handle bearings with a
hydraulic pump, therefore, a pressure gauge shall be
provided to each blade handle and each seal, the
pressure shall be maintained at 2kg/cm
2
for a
continous 12 hours, and the pressure drop shall not
exceed 0.2bar during the process of appling pressure.

(6)Assembly of
guide bearing
components

1. Overturn the impeller for 180
.(blade handle
hanging on steady bearing.).
2. Push it into the hole of impeller guide ring through
blade handle in accordance with the preassembled
guide bearing components of figure 5-2 until the
side surface touching the nut of blade handle.
3. Toggle sealing O-ring and maze-design sealing
push-in blade handle and bearing tray, lubricating
grease shall be applied to seals, fitting surface and
groove side in advance.
4. Put preloaded spring (belleville spring) on the
bearing tray which lies in the hole of guide ring.

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5. Preload the spring with retainer ring.
6.Loose blade handle nut slightly and take off the
filling block under balance weight.
7.Tighten blade handle nut until the preloaded
spring on bearing tray touching tapering annulus
(torque is increased abruptly). Maybe blade handle
nuts need further tightening to have the hlade
handle nut aimed at the groove of blade
handle.Wringing reversely is prohibitted.
(7) Disassembly
and assembly of
impeller
1.The disassembly force of wheel hub shall be fixed
at 300kN.

(8) Coupling
maintenance

No parts of RIGIFLEX coupling with detachable
flange hollow shaft is suffered from friction and
wear. The ratcheting of the flexible coupling is
pinned; its diaphragm is made of special high grade
spring steel, and the diaphragm shall be configured
in pair in order to allow the connected machine to
move freely in three directions.Such RIGlFLEX
coupling needs no maintenance and lubricating, and
is unlikely to be out of commission..
1.Assembling:
Loose joint bolt from the complete set of coupling,
disassemble intermediate shaft. The heating
temperature of coupling shall not exceed 150
when installing the half couping on mechanical main
shaft head that is reday for connecting. Heating
shall be carried out in heating furnace which can
provide temperature control to avoid flame heating,
since local overheating will weaken the strength of
coupling parts.
Intermediate shaft shall be installed with proper
distance M. Note: after the alignment of central
connecting bolts of flange hallow shaft, the
diaphragm is not allowed to be of bending but can
only extend parallelly along the flange in normal
position.
2.Alignment:
Perform precise alignment of the coupling,

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provided the opening size is Y
. Both of opening size Y
max
and Y
min
shall be
measured out( figure 5-8). Displacement deviation
will be caculated based on the measured value.
Table 5-2 Size Y used for aligning the coupling
precisely

Allowance
displacemnet of
each end side
(mm)
Couplin
g type
Openi
ng
Y(mm)
a
1max
r
1max

MA
(Nm)
1001 23.5 3 6.5 410
Allowance error for the alignment of RIGIFLEX coupling with detachable
flange hollow shaft

English Chinese
Grid-flexible coupling
Intermediate shaft
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: Allowance error of the coupling end surface
deflection (angle)
: Measured deflection value
Measured diameter
Allowance Error of Coupling Alignment
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Chinese English
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Intermediate shaft
: Allowance error of the coupling end surface
deflection (angle)
: Measured deflection value
Measured diameter
VIII Attachment VIII: Allowance alignment error
of intermediate shaft

Maintenanc
e item
(1) Radial displacement:
r
1
Ymax-Ymin (mm)
100r
1
/ r
1max
%
1

Refer to table 5-2 for the value of r
1max
.
(2)Axial displacement:
a
1
(Ymax+Ymin)/2-Y (mm)
(Note:+ a
1
refers to the couplings being detached
from each other; -a
1
refers to the couplings being
combined.)
100a
1
/
1max
%
2

Refer to table 5-2 for the value of a
1max
.
Generally, r
1
0.20mm will
meet operation
requirements.
(3) Allowable values of the radial and axial
displacements interrelated percentage, which shall
comform to the following formula:

1
2
100%
E.g.:if 40% of
1
has been used, 60% of
2
can
be used at most.
With the alignment finished, tighten the joint bolts
in accorance with the tightening torque of table

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5-2.
(9) Stagger
angle
measureme
nt of the
blade
Check whether on-off angles (position) of the
max. and min. blades are +15 and
-30respectively. Methods: measure out the
included angle between blade section and air flow,
then check whether the measured angle matchs
the indication value shown in blade angle dial.

Tightening Procedure Chart of Impeller Fixing Bol t

Hydraulic Regulating System Chart of Force Draft Fan
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English Chinese
Blade
Regulating bar
Piston
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Hydraulic cylinder
Piston shaft
Control head
Servo valve
Regulating bar
Control shaft
Indication shaft
Return oil
Pressure oil
Regulating bar
5.3 Induced Draft Fan Maintenance
5.3.1 Technical specifications of induced draft fan
Fan model: Axial Induced Draft Fan with Meridional Acceleration
Fan type: G158/273
Manufacturer: Shanghai Blower Works

Installation site: Vietnam Quang Ninh Power Plant
Project No. of Shanghai Blower Works:2007-20
Direction of rotation: The impeller rotates clockwise being seen from the direction of air
flow.
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Assembly Schematic Diagram of Induced Draft Fan
Fan Aerodynamic Parameters:
Serial
No.
Project
Name

T.B

BMCR

1 Fan inlet caculated flow
(m
3
/s)
281.39 232.5
2 System total pressure drop
(kpa)
4053 2895
4 Fan inlet flue gas
temperature ( )
138 127
5 Flue gas density (kg/m3) 0.85 0.883
6 Fan inlet dust content
(mg/Nm
3
)

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7 Rotate speed r/min 735
8 Fan shaft power (KW) 1416 809
9 Fan efficiency (%) 79.33 79.63
10 Fan rotary inertia
(J=0.25GD2)
330KgM2
11 Motor YKK710-8
5.3.1.1 Mechanical parameters
Fan inside diameter 2740
Impeller diameter 2730
Impeller series 1
Blade model 14G16
Blade number 14
Blade material 15MnV
Clearance between inside diameter of the casing and outside diameter of the blade
4-5.4mm
Regulating means: Inlet damper
Coupling type: Rigid-flexible coupling, specification: 5001Form14,
Support pattern: Double bracing
Weight of machine:( Heat insulating layer not included): 46152 kg
5.3.1.2 Performance curve
Fan type: G158/273
Customer: Quang Ninh
Power Plant

Fan rotate speed: 735r/min
Motor power: 1500KW
Fan blade model: 14G16
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5.3.1.3 Fan starting torque
Fan rotate speed: n=735r/min
Moment of inertia of rotor: 330 kg.m
2
Fan power (under max. working condition) 1416KW
Motor power 1500KW
Motor voltage 6600V
Being seen from the motor shaft end, the motor rotates clockwise, and the fan rotates
anticlockwise.
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Chinese English
Fan torque
Fan rotate speed
Full open of inlet guide blade
Full close of inlet guide blade
5.3.2 Function description
The fan is a variable stator blade induced draft fan designed and manufacured by our
company with the imported technology of Germany TLT Corporation.
The gas passes throuth the inlet regulating device of gas inlet box, and then enters into
impeller in a flow angle direction that corresponds with the inlet guide blade; it obtains the
needed energy of overcoming resisitence derived from pipe networks in the impeller.This
presents with total pressure rising of the gas.
In the variable stator blade induced draft fan, the realization of total pressure rising of gas
medium in the impeller relies largely upon the increase of dynamic pressure, while the
conversion of dynamic pressure to static pressure is realized in straightening guide blade and
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disffuser.
The impeller of the fan is designed in accordance with TLT developed G158 blade model,
with the characteristics of high efficiency and easy fabrication, and its working condition is
particularly well adapted for the induced draft fan of large scale power station.
5.3.2.1 Still Parts
Including the following components: (in the order of air flow direction)
Gas Inlet Box (52.00)
Flow through the rectangle inlet cross-section of gas inlet box, after a 90 turn, then axially
flow into inlet guide regulating device (87.00) from outlet circular passage of gas inlet box.
Inlet Guide Blade Regulating Device (87.00) 125
Inlet guide blade regulating device is equipped with airfoil-shaped front guide blade, and
connected with regulating mechanism, when the regulating mechanism acts to adjust, the fan
inlet front guide balde is brought to different positions to change the flow angle of fan inlet, thus
higher efficiency can be attained in different working conditions to adapt to the requirements of
boiler variable working conditions.
Casing (51.00)
It is an outer shell of the fan. By suitable treatment on the inside diameter, a clearance of
4-5mm between the casing and impeller shall be ensured.
There exists a set of fixed straightened guide blade (rear guide blade) in the backside of
the casing.
Diffuser (55.00)
The diffuser bears a certain diffusion angle; with the area increase of the flow passage, the
flow rate of the fan will decrease, converting the dynamic pressure to static pressure will made
transportation and deinstallation much easier.All of the above still parts are allowed to be
dissected.
5.3.2.2 Rotor
Mainly consists of:
Bearing box (11.00):
In consideration of thermal expansion influence, the casing and the diffuser is flexibly
connected by shroud so that thermal expansion cannt be a danger to the rotor under any
circumstances.
There exists two bearing boxes to support impeller weight and sustain the axial thrust
derived from air flow during the operation of the fan. Bearing box adopts split type, and is
featured by easy and reliable adjustment and installation.
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Impeller (12.00):
Impeller consists of impeller casing, stud and blade, and the whole impeller adopts welding
structure to reduce weight. blade the blade is produced in line with certain mode line heat
moulding, and welded on to wheel hub at a certain stagger angle. The impeller connects with
the main shaft firmly through high strength bolt.
Shaft description (11.11)
In order to faciliate the assembly and disassembly of impeller, the shaft is designed to be
sectional and flange is used to connect adjacent two sections; flange that connects the impeller
is welded on the shaft. Power transmission between coupling and shaft is delivered through fit
key, while power transmission between fan shaft and impeller is realized by virtue of fitted bolt.
Bearing description
Bearing block description
Double-row self-aligning spherical roller bearing is installed in horizonally-split bearing, and
cylinder hole is applied to the shaft directly.
Top and bottom bearing boxes are connected through four bolts and riveted through two
taper pins to guarantee correct installation, the end cover of the bearing boxes is a one-piece
structure and is connected through bolts with bearing box, the footing of bearing box is provided
with bolt hole to faciliate the connection with bearing box chassis through bolt, moreover,
alignment hole used for aligning with taper pin is furnished.
Bearing box is especially designed for fixed bearing and floating bearing, so it is
unnecessary to house additional retaining ring in the bearing box. Total axial displacement of
floating bearing approximates to 10mm.
Frame description
Floating bearing block is located on the bearing bracket of straightening guide blade; motor
YKK710-8(29.00) has its own chassis; bracket of fixed bearing box (11.14) is directly mounted
on foundation.
Coupling carries coupling guard to prevent contact with the environment.
Transmitted force of gravity and all possible equilibrant force are taken into consideration
when designing the brackets.
Grid-flexible coupling (25.21,25.22):
The project adopts 5001form14 type grid-flexible coupling, the main shaft connects with the
fan and the motor through coupling respectively. This type of coupling can perform a certain
amount of axial, radial and angular displacements, and can compensate the thermal expansion
during unit operation, various displacements incurred in the process of manufacture and
installation to ensure steady operation.
Cooling fan
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Floating bearing box of the fan is located within straightening guide blade loop, in order to
be free from the influnce of medium temperature, it employs 4-72-11 No 3.2 centrifugal fan,
which is introduced by cooling air duct from the backside of diffuser.
Thermometer
Temperature of the main bearing of the fan is measured through resistance thermometer,
and each bearing block is furnished with three thermal resistance thermometers to measure the
temperature, collected signal will be sent to central control room.
Vibration-measuring detector: each bearing block is provided with a vibration sensor to
measure the vibrating amplitude of bearing block in horizontal direction.
Other spare parts
The fan is also equipped with instrumentation for gauging bearing temperature vibration, oil
level and fan surge, which can provide telemetering, monitoring and interlocking functions to
ensure the operation stability of the fan.The fan is also provided with interface for measuring
gas pressure and temperature for the user to detect air volume and air pressure.
5.3.2.3 Regulating device
Regulation of the fan capacity is achieved by means of the inlet guide regulating device. When
the regulating device is adjusted, the stagger angle of fan inlet guide blade will be adjusted
synchronously. As for a specified fan capacity, optimum prewhirl can be made available to
medium by regulating front guide blade stagger angle of the impeller. The fan can achieve
higher efficiency than throttle governing type under variable working conditions. Because the air
flow directions are almost axial in the simple throttle governing type and bear no relation to the
actual capacity of the fan.
The inlet regulating device adjusting the inlet static blade angle by means of the regulating
mechanism of electric actuator is feasible. Electric actuator operates on the basis of automatic
control provided pulse signal as required by plant capacity. Electric actuator connects with the
position loop of inlet guide blade regulating device by means of steel operating lever. When the
electric actuator acts, position loop rotates together, thereby regualtion can be achieved
through winch, connecting rod and the changing of the inlet guide blade angle.
5.3.3 Parts description
5.3.3.1 Impeller
Welded structure of the impeller can relieve the its rotary inertia, the blade is formed by
uniform steel in line with certain mode line heat moulding. The impeller and the main shaft of
bearing box is jointed togrther through adapter sleeve. In order to ensure the clearance
between the impeller and the casing, outside diameter of the impeller is guaranteed by lathe
and inside diameter of the casing is guaranteed by vertical lathe. Being seen from the air flow
direction, the impeller rotates anticlockwise.
5.3.3.2 Bearing box
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Bearing box adopts split type; bearing is cooled by cooling water. They are safe, reliable
and of compact connection. Each bearing box is equipped with double-row self-aligning
spherical roller bearing to support impelller weight and the axial force incurred by the pressure
rise of the fan.
5.3.3.3 Grid-flexible coupling
The unit employs grid-flexible coupling transmission, which is manufacured by our
company with the imported technology of Germany BSI Corporation and is a coupling that can
achieve actual balance.It can balance various displacements to be generated during the
process of installation and operation of the fan. (including axial displacement, radial
displacement and angural displacement) the coupling is very convinent for alignment. No parts
will suffer friction or fret during the operation of grid-flexible coupling. The flange of such
coupling is made of low alloy steel. Elasticity film with high dimensional tolerance requirement is
made of special high quality steel. Paired configuration of the elasticity film can allow the
connected machine to move in three directions freely. Maintenance is not required for this kind
of coupling. It is unnecessary to lubricate, and it can work without fault below the temperature of
150C.

5.3.3.4 Inlet guide blade regulating device
In the actual cases, fan will meet the situation of various operation requirements. It will
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change the inlet air flow angle through regulating inlet guide blade angle, so that the fan can
answer the boiler to gain better performance under different operating work conditions (loads).
this is the so-called prewhirl.

1.Regulating device shell 2. Regulating position loop3.Roller (radial direction) and bolt
4.Roller (axial direction) and bolt 5.Connecting rod 6.Regulating blade
7.Top regulating shaft bearing 8.Top shaft of root regulating bearing
9.Top shaft 10.Root shaft 11.Joints
5.3.4 Induced Draft Fan Maintenance
Maintenance
Item
Workmanship and Precautions Quality Standard
1. Motor bearing

1. Open the top cover and remove
the oil ring. Open the upper bearing
and measure the top clearance and
side clearance to duely record before
maintenance.
2. Use jack to jack the rotor so to
remove the bottom half bearing and
spray with lead red to grind at the
shaft gland. Check the contact
surface and repeat the grind several
times till the joint satisfies the
1. The top clearance shall be 0.32
0.48mmthe side clearance
shall be one half of the top
clearance, that is 0.16-0.24mm.
2. The clearance between the oil
seal diameter is 0.40-0.60mm
3. The tension of the joint
between the upper bearing and
the bottom bearing shall be
0.00~0.03mm.
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specifications.
3. Clean the bearing seat inside and
check overall the bearing casing.
4. Put down the bottom half bearing
and remove the jack and put the rotor
to the shaft bearing. Measure the
side clearance. Take 3
measurements at each side and use
lead method to gauge the top
clearance.
5. Check and repair internal oil seal
and measure the clearance.
6. Measure the clearance between
the shaft beraing and bearing
casing.7. Check the oil ring and
repair.
8. Check the clearance of external oil
seal and repair. 9. Clean the oil
piping and replace with new flange
gasket.10. Clearly mark the position
before maintenance or find the
original marking. Shaft bearing oil
inlet has to be aligned with the oil
inlet hole on the bearing casing.
1. The front and rear bearing seat oil
inlet has to be installed with throttle
orifice.
4. The contact of the bearing shall
be 2~3contacts/cm
2
.
5. The medium gasket of the
bearing shall not exceed 0.30mm.
6. The clearance between the
bearing and shaft gland shall be
19mm.
7. The rear bearing seat has to be
insulated. The leg has to be on an
insulation plate. The bolts have to
use insulation tube and oil pipe
has to have insulation sleeves
. The oil ring has to be Ok. If it is
worn or deformed, replacement
must be done. The bottom half
has to be immersed in the bearing
seat.
9. The throttle orifice oil inlet
pressure shall be around 49kPa
and the oil filter pressure around
98kPa. There shall be little
difference between the front and
rear pressure.
2. Maintenance
and Service of
Diaphragm type
coupling

1. Check whether diaphragm spring
is Ok.
2. Check whether the bolt connecting
the spring is loose.
3. Check whether the coupling in the
middle of the half coupling is Ok.
1. The spring gasket shall be
complete.
2. The joint shaft and middle
flange shall be complete without
any damage.
3. The bolts connecting the spring
shall be tight.
4. The temperature of the joint
shaft when being heated shall not
exceed 150 . No heating from
fire directly to prevent any
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overheating.
5. Tighten the coupling on the
shaft with a clearance of 0.00
0.04mm.
3. Disassemble
the rotation part
of the fan

1. Remove the bolts on the casing
and the position pin and the casing.
Lift the upper casing according to
TLT rules. Care shall be given to the
lifting and damage to the blade is
prohibited.
2. Cut 0.5-1mm from the front part of
the middle shaft hood and make two
adjustable support to support the
middle shaft. Then remove the flange
bolts between the middle shaft and
coupling and use bolt to tighten the
middle flange in its opposite direction
to press the spring to contract so that
there is clearance between the
middle flange and middle shaft. The
clearance is to be used to lift the
impeller. 3. Loosen the shaft gland
round nut safe and the round nut.
4. Get ready the special tools for
disassembling the impeller. When
disassembling the impeller, first lift
the impeller to prvent damage to the
blade. After disassembling, the
impeller shall be placed to special
support or timber and covered with
waterproof materials to prevent dust.
5. Remove the disaposable bolt
between the bearing seat and casing.
6. Remove the temperature
measurement at the bearing seat
together with oil inlet, return oil piping
and pipe and packed with plastics.
7. Slowly lift the bearing box and
place it on the asessbling support
1. The torque for the disposable
bolt connecting the bearing casing
and casing shall be 250Nm.
2. The torque for impeller lock
bolts (disposable)shall be 300Nm.
3. The maximum and the minimum
clearance between the bearing
rear end cover and casing are
0.80mm and 0.20mm respectively.
They shall be sealed tightly.
4. The added oil shal comply with
specfications made by the
manufacturer.
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and fixed.
8. Loosen the bearing end cover
screw and remove the impeller end
cover9. Put the bearing in an upright
position and extract the rotor.10.
Use a puller to remove containment
shell, and remove bearing end
cover and retaining ring and twin
thrust bearing.11. Check, clean or
replace bearing. 12. Replace all
sealing parts. 13. Check whether the
bearing seat casing and the end
cover is Ok. 14. The order of
sequence for assembling and
disassembling is opposite and clearly
measure the clearances and record.
15. Precautions during
disassembling: mark every part
before disassembing and assemble
according to the marks made. All
high tension bolt shall be tightened
with specified torque. On the bolt
shall sprayed with supramoly. On the
bearing seat end cover shall be
sprayed sealants so that it is oil
leakage free. 16. After placement of
the rotor, no gasket shall be added
between the bearing seat and
casing.17. Impeller shall not be in
any leaning position. Use filler gauge
to measure the clearance at the
bottom of the coupling. The bolts can
only be tightened when the 0.03 filler
gauge can not be inserted.
4. Check the
Main Shaft Gland
and its level

1.When the rotor is positioned, use
level to measure the level of the
coupling shaft gland.
2. Check the key groove and key and
upper tooth and repair
3. The key groove is Ok with no side
1. The shaft gland shall be
smooth, without cracks, curvers,
or burrs. If there is abrasion,
repair needs to be made. The
ovality and concentracity outside
of the shaft gland shall be 0
2.The impeller assembling
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clearance and the tooth is Ok.

position shall shine with bright
yellow colour after copper spray.
There shall not be any black
colour.
3. The level of the shaft shall be
0.06mm/m.
5. Middle Shaft 1. Check the appearance of the
flange, the screw holes on both sides
to see whether there is damage.
2. Use microcalipers to measure the
Out-of-roundness.
3. Meausre the bending on a
specialized motor support.
The flange at both ends shall be
complete without any damage.
The screw hole is Ok. The hollow
shaft shall be no cracks,
damages. The balance weight
shall be fixed and tightened. The
bending shall be , the out of
roundness shall be 0.02mm.
6. Impeller
maintenance

1. Remove the fouling on the
impeller.
2. Before removing the hub, check
whether there is seal on it. If no, first
make seals on the hub.
3. Measure the wear of the induced
draft fan and the blade and record
duely.
4. There shall be no cracks and
deformation from appearance of the
blade.
5. Remove the hub from the main
shaft and place it on a special
support.
1.The blade surface is smooth
and without damage, deformation.
The hub is complete.
2. Inside the hub were no
impurites and foreign matter.

7. Measure the
radial clearance
between the
blade and
casing.
Measure the up, down, left and right.
If the clearance is too small, use
grinder to grind the blade or casing
wall.
The tolerance for the clearance
between the blade and the casing
is 5~7mm.
8. Crosscheck
with the
openness and
closure of the
inactive entry
1. Close the inactive entry 100% and
check whether the trundown ratio is
consistent or not. If not, then adjust
the external articulated parts so that
the turn down ratio is the same. At
When the blade opens +30 or
closes -75, refer to the casing
scale.
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the same time, the casing scale
indication shall read 75. The
position at this time shall be set as
0%.
2. Use the actuator to manually
adjust the entry blade to fully open.
At this time, the scale indication on
the casing shall read 30. The
position at this time shall be set as
100%.
3. Fix the position of stop pad for the
actuator.
9.Alignment of
the fan and the
middle shaft
motor.

1. Use fan as the reference and move
the middle shaft to find the
concentricity. Then move the motor to
find the concentricity between the
motor and middle shaft.2. After
alignment and motor runing without
load, connect the coupling and
remove the temporary support for
the middle shaft and return the
shaft hood and coupling hood.3.
Use Dial Indicators to measure the
center.

1. The radial clearance between
the coupling hood gland seal and
coupling shall be 1~2mm
2. Requirements for the
alignment of diaphragm coupling
at the impeller side and motor
side before the pre-lift of the
motor shaft: radial displacement
r10.15mm; axial displacement
a10.10mm. The requirements of
alignment of diaphragm coupling
after pre-lift of motor shaft: motor
side upper opening and impeller
side downside opening radial
displacement r1=0.20~0.30mm;
left and right opening radial
displacement r10.2mm; up,
down, left and right opening axial
displacement a10.15mm.
3. Alignment requirements after
the coupling is pre-elongated:axial
displacement a1=2.20.15mm,
radial displacement r10.2mm.
10.Casing Inlet
and outlet
compensator
maintenance or
1. Repair the compensator.Replace if
there is serious damage.
2.After repair, check and repair any
1.The compensator shall be
complete, without damage.
2. The tightening plate shall be
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replacement air leakage. complete.
10. Induced draft
fan cooling fan
1.Clean the filter.
2. Check impeller wind duct
3. Reversible deflector maintenance.
4. Motor maintenance together with
its electric supplies. motor.
5.Trial operation
l. The filter, after cleaning, is
complete.
2.Both the impeller and the fume
duct is Ok, without fouling.
3. No vibration and abnormal
noise during trial operation.
12. Induced draft
fan inlet and
outlet fume duct
leakage repair
1. Check the inlet and outlet fume
duct. If there is leakage, repair by
welding with iron plate to remove the
leakage.
1. Replace is the abrasion
reaches 1/2 of the thickness.
13. Induced draft
fan airinlet
chamber and
diffuser
examination and
leakage repair
1. Eliminate manhole air leakages
2. Check the airinlet chamber and
diffuser. If there is leakage, repair by
welding with iron plate to eliminate
the leakage.
1. The manhole is complete,
without air leakage.
2. Replace the inlet chamber,
casing, and diffuser if the
abrasion reaches 1/3 of the
thickness.
14. Outlet guide
vane
examination and
repair by welding
Check and clean the outlet guide
vane. If it is worn, repair by welding.
Replace if the abrasion of the
outlet guide vane reaches 1/2 of
the thickness.
15. Induced draft
fan inlet and
outlet isolating
valve
maintenance
1. Check the whether the damper
switch is correct or not and adjust.
2. Check whether the ram pins are
complete and Ok.
3. Check whether the bearings are
Ok and whether there is lubrication
oil.
1. The baffle is complete and its
opening and closure is flexible.
The turn down ratio on the inside
and outside is consistent.
2. The ram pins are complete,
without damage.
3. No corrosion, falling, or
congestion of the bearings. Inside
the bearings is there lube oil.
16. Trial
operation to
measure the
vibration and
calibrate the
1. After maintenance and in the trial
operation, the fan must satisfy the
following:
1) No impurities within the rotation
1.The vibration value 0.10mm.
2. The bearing operates Ok,
without abnormal noise, and oil
leakage. The bearing temperature
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balance.

parts.
2) Normal oil circulation established.
(3) Remove scaffolding and clean
the site.
(4) People shall stand in the axial
direction in case of accidents.
2. Measure the vibration value during
trial. Check whether is abnormal
noise from the leg screws and the
rotation parts.
3. Calibrate motion balance if
necessary. The balance weight shall
be welded to the rear side of the hub.
shall not exceed 90 .
3. The trial operation shall be 2
hours.
4. The non-static blade can be
adjusted flexibly.
5. After balancing, the thickness
of the balance weight shall be
less than 10mm. The welding
area shall satisfy with the
minimum area on TLT rules. If
tightened with bolts , the size of
the bolt section shall be at less on
half of the welding area. 6.
Regarding the vibration caused
by blade imbalance, the balance
weight has to be marked and
logged so next time it can be
removed when replacing blades.
After removing the rotor blades,
according to TLT rules, it shall be
marked with a bright color
BLADES
5.4 Maintenance of Fume duct and Air duct
Fume Duct, Air Duct and Flange
Maintenance
Item
Workmanship and Precautions Quality Standard
1. Check the air
duct.
1. Check the air leakage of the air duct.
2. Check whether there are defects such
as cracks and deformation.
3. Check whether there are weld
openings, cracks in the air duct
strengthening parts. .
1. No cracks on the air duct
iron plate and strenghthening
parts.
2. The air duct shall be sealed
without air leakage.
2. Air duct and
flange
maintenance

Check whether there is weld openings in
the air duct. 2. Air duct flange packing
seal maintenance.
3. Weld to repiar or remedy the cracks in
the air duct and strengthening parts to
1. No welding defects shall no
noticed on air duct welding.
The joint shall be smooth.
2. No cracks on air duct and
strenghthening bars.
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eliminate the cracks
4. After the air duct maintenance, the
impurities shall be cleared out and the
temporary fixations be removed. 5. Do air
pressure examination and check the seal
quality.6. If there is leakage, it shall be
handled timely. 7. If the air duct vibrate,
analyze the causes and handle them
accordingly.8. Air duct thermal
preservation.
3. No random flame cutting on
the flange bolts. Mechanical
processing shall be adopted.
4. After pipe and equipment
maintenance, immediately
clear all the foreign matters,
dusts and temperary fixations.
5. There shall be seal jacket
between the air duct and the
equipment flange. The jacket
shall not enter either the air
duct or the equipment. Both
sides of the jacket shall be
sprayed with seals.
6. The rear center line
deviation after the air duct
maintenance shall not be
bigger than 30mm.
7. The air pressure experiment
shall comply with regulations.
Fume Duct and its Accessories
Maintenance Item Workmanship and Precautions Quality Standard
1. Baffle and
Plugboard and their
Operatio
Mechanisms
1. Check the new baffle and plugboard
before installation. Do disasembly check
if necessary.
2. Leave heat expansion clearance as
per the drawings.
3. Gland seal maintenance and
replacement to eliminate leakage.
4. Mark on the shaft gland corresponding
positions of the baffle and plugbards as
per the actual positions. Their opening
and closure shall not be limited.
5. Maintenance and check the opening
degrees of combination type baffle.6.
Check the seal of the baffle. If worn,
replace immediately. 7. Check whether
1. The baffle and plugboard shall
comply with the design
requirements.
2.The expansion clearance shall
comply with the design
requirements.
3. The gland seal shall be Ok,
without leakage.
4. The opening and closure of
the baffle and plugboard shall be
accurate and flexible.
5. Regarding the combination
type baffle, the opening shall be
syncronized and the turndown
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the indication in the remote control
equipment is correct; whether the
welding seat opens; whether it is leveled.
8. Check the abrasion level on the
mechanisms with universal joint.
Depending on the level of abrasion, to
decide whether it needs to be repaired or
replaced.9. Check the marking for open
and close and also the limiter for fully
open and fully closure. 10. Clean the
fouling in the fume duct.11. Check the
abrasion level of baffle in the fume duct. If
there is serious abrasion, replace
immediately.
ratio consistent.
6. The operation mechanisms
shall be convenient to use with
correct indications. The seating
plate shall be fixed and leveled.
7. The universal joint shall be
Ok, and the abrasion degree
shall not exceed 1/10. The
rotation degree shall exceed
30.
8. The opening and closure
indication shall be clear and
comply with the turndown ratio
9. The fume duct shall be clean,
without fouling.
2. Extension
maintenance
1. Check the movement of the extension
to ensure free movement. 2. Replace the
fillers each time the extension is
maintenanced. The flange bolt to the filler
shall be flexible.3. Eliminate cracks on
the extension. 4. Check the abrasion
level of the internal tongue in the wavy
extension. If it is serious, either repair by
welding or particially replace. If the
extension as a whole is worn, or the wavy
extension is corrosioned seriously,
replace them as a whole.
1. The movement of the
extension shall be flexible.
2. The fillers in the filling
extension shall comply with
standard.
3. No defects such as cracks on
the extensions.
Support and Hanger
maintenance
1. Check the support and hanger of the
fume duct. If there are cracks,
loosenings, deformations, they shall be
handled immediately.
2. Check the movement and the abrasion
level of the movable support and hanger.
3. Check the spring in the spring hanger
to see whether there are cracks or not.
1. The support and hanger shall
be complete and Ok, without
breakage, cracks, loosening,
and deformation. The load on
the hangers shall be balanced.
2. The movable support, after
being loaded, can still freely
move. Replace the support if the
abrasion exceeds 1/3 of the
walling of the support.
3. The spring on the hanger shall
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comply with design requirments.
No cracks shall be on the
springs.
5.5 Air Heaters and Pipe Maintenance
Air Heaters Maintenance
Maintenance Item Workmanship and Precautions Quality Standard
1. Check the air
heaters
1. After stopping the boiler, water shall be
circulated to check whether is leakage from the
air heaters. Record the leakage position if there
is any.
2. Check the abrasion level of the air heaters.
Replace the worn parts.
3. Check the corrosion degrees of the air
heaters and clearly record them. Replace the
parts which have serious corrision degrees
4. Check the fouling conditions among the
radiators of the air heaters. Clean the fouling
timely to ensure the fume flow area.
1. There shall not be
any leakage from the
air heaters.
2. The abrasion level
of the air heaters
shall not exceed 1/3
of the original
thickness.
3. There shall not be
fouling in the air
heaters. The fume
flow area shall not be
less than 90% of the
design area.
2. Maintenance of
the Air Heaters
1. Replace the damaged air heaters.
2. Hydrotest must be carried out before the air
heaters being installed.
3. When removing the damaged air heaters,
measures have to be taken to prevent damages
to other heaters and to ensure the security and
safety of the site.
4. The welding quality shall pass deficiency free
test by radiation.
5. Hydro test for the whole set shall be carried
out after replacement of the air heaters to
ensure there is no leakage.
6. Hydrotest check shall be executed on each
maintenance and service after the air heaters
are put into operation.
1. New air heaters
have to undergo
hydrotest to ensure
no leakage. The test
pressure is 1.25
times of the work
pressure.
2. After the air
heaters are put into
operation, the
hydrotest pressure
shall be its work
pressure. Normally a
hydrotest with 1.25
times of the work
pressure shall be
carried out around
every 6 years.
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6 ESP
6.1 ESP Technical Specifications
Name Technical specifications parameters
Manufacturer Shanghai Metallurgical & Mining Machine Manufactory
Product type FAA ESP
Nominal flue gas flowing area(m2)
Flue gas flow (m3/s)
Pressure drop of ESP proper (Pa)
Design efficiency (%)
2*269
258.98
<195
99.75%/99.7%
6.2 Structure of ESP
The method utilizing HV electrostatic field to act on dust gas is called electrostatic
precipitation and the equipment is named electrostatic precipitator (ESP). Its operation principle
is that: in HV electrostatic field, gas is ionized by the electric field force into electrons and ions.
These electrons and ions move under the action of electric field force and combine with dust
making dust charged. Dust particles with negative electric charge are collected at anode
(collecting plate), discharged and adhere to the anode. Meanwhile, particles with positive
charge are collected at the cathode. When dust accumulation reaches a certain thickness, dust
particles will be peeled off from the collecting plate by rapping mechanism and drop into ash
bucket. The dust collecting process finishes.
Major features of ESP are: high efficiency; low operation resistance; low operation cost.
However, cost of ESP is high, and its volume is huge requiring a large area. In addition, it has
strict requirements on manufacture, installation and maintenance. Efficiency is easily to be
affected by operation factors. Therefore, operators should have high technical capability.
An ESP is composed of one or more chambers and fields. Devices include discharge
electrode, collecting electrode, rapping unit, ash bucket, ash discharging device. So-called
chamber is a sub branch of transverse flue gas path. There may be single chamber, double
chamber or triple chamber according to flue gas volume. So-called Field is a dust removal unit
along with the direction of gas flow. Each unit has an independent working system.
6.3 Maintenance of ESP
1. Get Equipment Conditions before Maintenance:
Include: operating parameters of electric fields before ESP outage (secondary voltage,
current,ratio of putting into operation, operation hours, etc.); equipment defect and treatment
records; summary of last overhaul and operation maintenance logs since last overhaul (such as
technical improvement and equipment replacement).
2. Prepare Maintenance Schedule:
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Include: progress control schedule; maintenance procedures; labour arrangement and
diciplines coordination; special technical provisions and safety procedures.
3. Material preparation and site arrangement:
Include: preparation of spare parts, maintenance material, construction tools, safety facilities,
lighting tools and protective clothes; division of working area and stack area; management of
site spare parts.
4. Preparation of technical record forms:
Include: measurement record forms of electrode distance, record form for no-load step-up
test of electric field universe point, distributing test of air flow, rapping acceleration test, air
leakage ratio test record forms(if necessary).
Safety Measures and Precautions during ESP Maintenance
1. Maintenance activities inside ESP and at high-altitude should be performed as per
requirements specified in [Working Regulation of Power Safety].
2. Maintenance inside ESP should be carried out after boiler is shut down and cooled by
natural cooling or draft cooling, and the temperature of the electric field is below the safety
value as well as the residual flue gas is exhausted. The safety temperature is 40oC
normally. Properly extend the safety temperature limit as required and strengthen
protective measures. However, the temperature limit should not exceed 45oC.
3. Before enter ESP electric field, shut off the power supply, lay grounding wire and hang
warning sign.
a) Shut off power and hang warning sign: cut off the HV power supply with an obvious
breaking point and hang the warning sign. Cut off the power supplies of the ESP
auxiliary equipment (rapping, ash handling, and electric heater) and hang a warning
sign.
b) Discharge electric field and lay down grounding wire: after verifying the HV power is
shut off, put the HV disconnector to position Power-Grounding and lock it and hang
warning sign. Discharge the electric field with the grounding wire. Then hang a
warning sign written with grounded. Before open b manhole to get in electric field,
discharge the manhole and electric field. Insulation glove should be worn during
discharging and laying grounding wire.
4. Power supplies for electric field maintenance:
a) Voltage of the portable light should not be higher than 12V.
b) If a 220V or 380V maintenance power supply is needed to be routed into the electric
field, a guardian should be appointed outside the electric field manhole to quickly shut
off the power supply equipped with earth leakage protector in case of emergency. The
earth leakage protector should be qualified. Power wires should be well insulated to
avoid any accident.
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c) Welding wires routed into electric field should be well insulated without any damage or
leakage.
5. For maintenance inside electric field, working bags should be used for material
transportation. Count the material and tools before each commence and after each
completion. Remove debris produced by maintenance and do not leave them at electrodes
to prevent them from dropping into ash hopper or left in the electric field.
6. For maintenance inside electric field, there should be at least two personnel with another
for guardian outside the ESP manhole.
7. Special safety measures should be arranged for specific maintenance items:
a) Safety measures during no-load step-up test of electric field: the key points of the
activity are the combination of mechanical and electrical works simultaneously,
power-on test and discharge treatment.
b) Cross working. Parallel installed cable should be supplied on the HV side when double
power supplies are stepped up. Special safety measures include preparation of test
plan or procedures, determination of person-in-charge, guardian from appointed
personnel, reliable communication, guard fence and suspension of warning signs. It
should be approved by the safety supervision department of the factory when entering
the electric field to observe discharge point.
c) For the maintenance of equipment in the HV switch cabinet of the latter stage electric
field maintenance, the damage caused by the drift charge from the former stage
should be avoided.
6.3.1 Maintenance of Cathode Wire and Anode Plate
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Remove ash inside
electric fields
1. Only at least 12 hours after the boiler
flameout can open the manhole for
further cooling so as to avoid the
deformation of parts inside ESP caused
by sudden drop of temperature.
Access can be available only if the
temperature inside electric field drops
below safety value.
2. Check before removing ash: check
the ash accumulation inside electric field
including accumulation position and
degree. Check ash accumulation on
electrode plate and electrode surface.
3. Cleaning of ash accumulation in ash
hopper: before manual ash cleaning in
electric field, start the continuous
cathode/anode rapping and trough plate
rapping for mechanical cleaning.
Discharge ash through normal ash
handling method. For ash removed out
by manual method from ash hopper of
the electric field should be stored in bags
manually for transportation. For cleaning
ash in the ash hopper, personnel should
be dressed with cotton protective
clothing, boot and dust mask to avoid
any injury. Ash releasing port and
maintenance passage should be bright
without barrier. When opening the
manhole, do not face to the front of
manhole.
4. Ash cleaning in electric field: the
cleaning sequence should be manually
performed from upper to lower and from
inlet to outlet by means of compressed
air blowing. Water flushing is prohibited.
Keep original check record
and registration; analyze the
cause of abnormal ash
accumulation to provide
reliable information for
maintenance.
Avoid discharging ash
through manhole.
No ash accumulation, scaling
on the surface of parts after
cleaning ready for the
maintenance.
When cleaning the ash
accumulation on the anode
plate, do not shake it to avoid
deformation of anode plate.
thickness of ash accumulation
should be less than 5mm.
(I)Anode plate
maintenance
1. Check the deformation of a single
anode plate and correct the difference.
2. Check corrosion and electric
1. Flatness error <15mm,
diagonal error <10mm.
2. No burr or sharp corner
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corrosion of a single plate and repair
damaged anode plate as well as grind
the burrs and sharp corner.
on the surface of plate.
(II)Anode plate
maintenance
1. Check the fixing pin roll on the
upper cleat of the anode plate, buckle
bushing and fixed-position welding;
check the deformation and abrasion of
the square hanging lug and hanger.
Check for any splitting around electrode
plate tightened by the buckle bushing or
any sinking or displacement of total
anode plates and repair them.
2. Check for any splitting, sealingoff
or deformation on the anode plates and
repair them.
3. Check the fixing pin roll of the
lower cleat of the anode plates, buckle
bushing and fixed-position welding;
check for any splitting around electrode
plate tightened by the buckle bushing.
Check the anode plates for any
deformation or sealingoff.
4. Check the heat expansion
clearance between the lower anode
plates and ash hopper port for any
seizing, expansion or other resisting
sign.
5. There should be no obvious
convex-concave on the whole anode
plate by visual inspection. Replace them
in case of the thickness of the anode
plate is less than 50%.
1. Buckle bushing is not
loose; surrounding electrode
plates are not split; abrasion
of hanger is less than 1/3 of
original thickness. Total
sinking of anode plates is less
than 5mm.
2. No splitting or sealingoff
occurs on the connecting belt.
3. Buckle bushing is not
loose; surrounding electrode
plates are not split; rapping
rod is fixed in the rail with a
transverse clearance of about
4mm.
4. Heat expansion clearance
should be calculated as per
twice of the value when
temperature of the flue
reaches the high limit.
However, it should not be less
than 25mm. the two side of
the comb-shaped port should
be smooth without steps.
5. bending of plane should be
less than 10mm; difference
between two diagonal lines
should be less than 10 mm.
(III) Detection of
the distance
between the same
electrode of the
anode plates
Take the straight electrode plates in the
middle of the electric field as reference,
measure the distance between the same
electrodes. Measurement should be
carried out on three points along the
height of the electrode plate. ,
Measure and record as per
clauses specified in the GB/
T13931-92 [ESP performance
test procedure].
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(IV)Calibration of
the distance
between the same
electrode
When the distance between the same
electrodes exceeds the specified limit,
calibrate the deformed electrode plates.
Do not knock the surface of the
electrode plate if calibration is not
available, replace whole electrode
plates.
Each electrode plate should be tested as
per manufacturer standard test before
replacement. Assemble the plates as per
the former sequence and check their
straightness.
Allowance error of the
distance between the same
electrodes is 10mm. if the
deformation of electrode
plates significantly affects
ESPs efficiency, replace all
plates.

(I) Maintenance of
tube-shaped spine
wires

l. check spine passivation, balling and
dropping off; check spine wires for any
loosing or dropping off; combining the
check of distance of two different
electrodes, check the bending of the spine
wires; tighten, repair, correct or replace
them as required.
2. replace the spine wires :
(1) Visually inspect the new spine wires; it
should be plain without any twist.
Arrangement of spines matches the
electrode wire.
(2) During installation, tighten and weld the
connecting bolt on upper cathode wire.
The blot on the lower part should be loose
a half circle after fully tightening before
welding.
Arrangement of spines
satisfies the requirements of
manufacturer; the space
error between points is no
larger than 1mm; center of
the spine wires should
match the pipe center of
cathode small frame.

(II) Detection and
adjustment of the
distance of two
different electrodes

1detection of distance of two different
electrodes should be carried out after the
maintenance of large/small frame and the
distance between the same electrodes of
the anode plate meets requirements.
2. During detection of distance of two
Error of distance between
the same electrodes is no
greater than 10mm.

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different electrodes, record forms should
be prepared including electric field name,
passage number, detecting points
number, cathode wire number, staff, time
and results.
3 there are two method for detecting
distance of two different electrodes:
(1) Visual observation plus pin gauge. This
method can be performed by experienced
staff. By visual observation , find out
suspect passage and check it with pin
gauge. If the pin gauge passes through,
the distance of two different electrodes
meet requirements.
(2) Standard method. Perform as per GB/T
13931- 92 [ESP performance test
procedure] .
Normally two methods are combined,
ensuring passage distance of two different
electrodes meet requirements. Record the
actual distance of two different electrodes
of the typical passages.
4. Correction of the distance of two
different electrodes: for the electric field
where correction for distance between the
same electrode and large/small frame and
electrode wire as per standards, it can
ensure the distance of two different
electrodes within a standard range.
However, standard may be not fully
satisfied because of large work load, short
work period and lack of maintenance
method and equipment aging. Partial
adjustment should be carried out to ensure
all distance of two different electrodes
within limit. Spine wires can be adjusted by
changing the deflection of spine and
distance between two sharp points. The
number of the adjusted parts should be
less than 5% of total to avoid the changing
of the discharge center, which effect the

Refer to standard GB/T
13931- 92.

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discharge performance of the electric field.
6.3.2 Cathode, anode rapping unit maintenance
(I) Integrity check
of Rapping
mechanism
1. Combining with anode plate ash
accumulation check, check the anode
plates with serious ash accumulation.
2. Check and repair parts based on
the protective action of motor overload
during operation of rapping mechanism
and damage of drive connecting part.
3. Check and treat all fastening parts
in the path of rapping force and retaining
welding.
1. During normal shutdown,
there should be a thin layer of
ash on the electrode plat.
2. Under normal conditions,
rapping mechanism can be
turned manually without
motor overload trip.
(II)Rapping drive
mechanism
maintenance
1. Drive connecting parts
maintenance: check rapping universal
coupling, flange, and spring gasket for
any loose or rupture, and replace and
weld them in case of defects. Pay
attention to the expansion clearance of
the coupling connection.
2. Maintenance of rapping drive shaft:
check shaft sections for any twist and
whether the coaxiality meets the
requirements. For a certain deflection, it
can be adjusted by changing the shim of
the rapping bearing seat.
Replace the shaft with a over abrasion.
3. Maintenance of rapping bearing:
(1) Check and treat the center
variation, sealingoff and displacement of
the 4 rapping bearing supports.
(2) Check abrasion of the sleeve.
Replace it in case of rupture or over
abrasion.
(3) Check the rolling and seizing of the
small roller of the bearing. Replace it
Requirement on the
coaxiality is that the space
tolerance between two
bearings is 1mm, total length
of the shaft is 3m. the
abrasion of the shaft should
be less than 4mm.

Sleeve abrasion is less than
1/3 of the former thickness.
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when repair is not available.
(III) Maintenance of
rapping hammer
and rapping
striking anvil
1. Maintenance of rapping hammer:
(1) Check the connection of the rapping
hammer head jib, hammer beam and
hammerhead; check the fastening parts
for any loose, sealingoff, or damage.
Repair or replace the rapping hammer
shaking seriously.
(2) Check rapping shaft and its
connection. Correct and treat the
deflection based on the deflection of the
hammer point.
(3) Check abrasion and rupture of the
hammer. Replace the hammer with
rupture or over abrasion.
(4). manually turn the hammers and it
should be rotates freely without seizing
or collision. Pay attention to the
direction of the hammer when replacing
hammer with installation direction.
2maintenance of striking anvil:
(1) Check striking anvil for any loose or
sealingoff.
(2) Check striking surface and repair the
depressed part to ensure line contact
between hammer anvils; replace the
striking anvil which can not be repaired.
(3) Check the contacting of the hammer
and anvil. The hammer center value in
hot state can be observed via hammer
marks. For check in cold state, electrode
plate expansion should be taken into
consideration. The hammer strikes the
anvil surface when it drops freely to the
vertical position.
Position error of the actual
hammer point should be less
than 5mm; the contact line
between hammer and anvil
should be longer than 2/3 of
the total length of fully
contacting. Considering the
heat expansion, hammer
point in cold state is 5mm
below the center line. The
distance error to the anvil
surface is 5mm when the
hammerhead freely drops to
vertical position.
(IV) Maintenance
of cycloidal-pin
1. Disconnect the cable of the motor and
clean the reducer casing and seat
platform; dismount the chain cover to
a) Pin roll and pin bush are
free of bending or
deformation, the abrasion
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wheel reducer remove the chain.
2. Disconnect the coupling to remove the
motor and coupling.
3. Mark on the contacting surface of
reducer casing.
4. Make marks when dismounting
connecting rod of the universal joint and
proper contacting surface. Notice the
thickness of the former paper gasket of
the contacting surface. Recover the unit
as per former paper thickness and
marked position.
5. When remove cycloidal gear A
(marked on the gear), the mark A on
the end surface of balance wheel should
match the mark B on the other
cycloidal gear. Recover it as per former
relative position.
6. Collision should be avoided when
remove rings. When remove and install
the roller bearing on the eccentric
locking collar, support the bearing
together with the eccentric locking collar
by hands to remove it along the shaft.
7. When clean runner axle, gear sleeve
and gear casing, check related abrasion
and clearance. Verify the length of
runner axle; seal ring of oil-proof rubber
and its spring are all in proper
conditions. Otherwise, replace them.
Lake-shaped seal ring should be filled
with grease. Fill lube oil into the tank
until required oil level and verify the oil
level gauge is qualified.
8. Maintenance the bearing as per
regular procedures. Bearing is
normally installed in hot state with a
certain stress after installation.
9. When insert input shaft pin into
should be no greater than
0.05mm.
b) Cycloid gear is free of
crackle with an abrasion no
greater than 0.10mm;
pinwheel and pin gear sleeve
should be free of bending with
an abrasion no greater than
0.10mm.
c) Bearing inner and outer
rings and rolling element
should be free of crackle or
pocking mark. Replace it
when the clearance exceeds
limit.
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cycloidal gear, the clearance in relative
holes should be paid attention to. Do not
crash the spacer ring when position with
pin sleeve.
10. After assembly, manually turn the
high speed input shaft to check for any
abrasion.

(V) Test run of
anode rapping
system
1. When rapping system is reset,
manually turning the gear to check
rapping rotation and rapping points.
2. Electrically test run for 1h.

1. Turning gear is free of
seizing, fluctuation and
abnormal noise; the oil mark
is clear and the oil level is
proper.
2. Reducer is free of oil
leakage, temperature rise of
the bearing is less than 50K;
there is no motor overload.
Sound and vibration of the
motor and reducer are
correct.
Cathode rapping system
maintenance item workmanship and precautions Quality standard
(I) Integrity check
of the rapping
mechanism
Integrity check mainly focuses on anode
rapping except ash accumulation check
of the cathode wire.

(II) Maintenance of
rapping drive
mechanism

1. maintenance of the drive connecting
parts:
(1) Check rapping universal coupling or
dowel pin coupling, flange, connecting
bolt, spring washer for any loose or
rupture. Fasten, replace and weld them
if necessary. Pay attention to the
expansion clearance of coupling.
(2) Check engagement of the drive plate
for any over abrasion or damage which
affect the normal turning.
(3) Clean the ash accumulation on
electric porcelain shaft l with a soft cloth.
Check for any crackle and discharge.
Electric porcelain shaft should
have a vertical moving
(expansion ) clearance, which
is 10mm normally.
HV test standard for electric
porcelain shaft is the same as
that for porcelain sleeve.
error between the rotating
shaft and center of the
soldering cup is 5mm

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Replace damaged electric porcelain
shaft. Visual inspection and voltage
withstanding test should be performed
before replacement.
(4) Check the contact sealing between
drive shaft and casing; verify the center
lines of the drive shaft and dust shield
match; check the soldering cup for any
rust and remove it if necessary.
2. Sliding bearing : maintenance content
is the same as that of anode rapping.

cathode rapping
hammer and
rapping striking
anvil
Maintenance content is the same as that
of anode rapping.

(IV) Cathode
rapping reducer
maintenance
Maintenance content is the same as that
of anode rapping.

(V) Cathode
rapping system test
run
Test run content is the same as that of
anode rapping.

6.3.3 Maintenance of cathode suspension device and large/small frame
(I) bushing
suspension device
1. Visual inspection and maintenance :
(1) Wipe the surface of the support
porcelain sleeve with a soft cloth.
Check surface and support stress
surface for any mechanical damage,
insulation damage or discharge vestige.
(2) Check suspender and locknut, load
bearing parts for any mechanical
damage.
(3) Check corrosion of soldering cup and
the coaxiality of suspender and
soldering cup; remove the dust and rust
inside soldering cup.
1. Concentricity error between
soldering cup and suspender
is no greater than 5mm.
Manhole is airtight and has
been check; inside should be
cleaned.
2. HV test standard of
porcelain sleeve should be
1.5 times of the rated voltage
of the electric field. It should
not be broken through within
1min.
elevation error of the
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(4) Check the electrical connection
between HV suspension device and HV
switch cabinet wall bushing.
(5) Check sealing of the manhole.
2. Replace support porcelain bushing:
replace damaged porcelain bushing.
Before replacement, mark the fixed
position of the suspender bolt. Provide
temporary measures to keep the
balance of four supporting points to
avoid damage to porcelain sleeve new
porcelain sleeve is intact by visual
inspection; HV test is acceptable;
elevation error of the porcelain sleeve
in the same group ( totally four) meets
requirements.
porcelain bushings in the
same group should be
1mm.
(II) Cathode large
frame maintenance
1. Check the levelness and verticality of
the cathode large frame meet the design
requirements or not.
2. Check and repair the partial
deformation, sealingoff or splitting of the
large frame.
3. Check stairs on the large frame for
any loose or sealingoff and repair them.
Flatness error of the frame is
not greater than 15mm,
diagonal error10mm.
cathode large frame should
be vertical to the horizontal
plane with a verticality error
10mm and elevation error
2mm.
(III) Cathode
small frame
maintenance
1. Check the connection of the upper
and lower small frames and fixation of
the small frames on the large frame.
Correct, repair and weld in case of
bending, deformation or sealingoff.
2. Check plainness of the small frame
and correct it as required.
3. Calibration of small frame plainness
should be combined with the distance of
two different electrodes to ensure the
distance of two different electrodes
within specified limit.
Plainness error of the
installed and welded cathode
small frame is 10mm and the
diagonal error is 5mm. all
nuts and bolts for small frame
should be welded for
retaining. There should be no
burr on the welding position.
6.3.4 Maintenance of other auxiliaries of ESP
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maintenance item workmanship and precautions Quality standard
(I) ESP casing
maintenance
1. Check casing for any abrasion and air
leakage. Patching should be carried out
for abrasion and corrosion.
2. Check support pipe and lacing wire in
casing. Replace seriously worn parts.
3. Correct the deformation of the inner
wall of the casing and baffle.
Air leakage ratio of the ESP
is lower than 3%.
(II) Inlet smoke
chamber
maintenance

1 deflector before inlet smoke chamber:
(1) Check abrasion of the deflector and
support parts. Replace the seriously
worn parts. Anti-abrasion measures
should be provided for part used less
than an overhaul period.
(2) Check the arrangement of deflector
is in accordance with the former design;
carry out treatments like adjustment and
repair welding.
2. Inlet smoke chamber :
(1) Check and repair the abrasion and
corrosion of smoke chamber inner wall
and support as well as lacing wire.
Replace seriously worn parts.
Anti-abrasion measures should be
provided for part used less than an
overhaul period
(2) Repair and strengthen the depressed
position of the smoke chamber.
(3) Check air leakage of contacting
surface between the flange of the casing
and inlet smoke chamber. Replace
packing material if necessary.

grid plate

1. Check the abrasion of the support
pipe, angel steel and connecting bolts
for supporting and fixing air flow grid
plate. Replace the seriously worn parts.
2. Check abrasion of the air flow grid
When the abrasion volume
reaches 1/4 of the former
opening, or it has obviously
effect the efficiency of
dedusting, replace it.
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plate. Repair seriously worn part. Take
anti-abrasion treatment if necessary.
Find out the cause of over abrasion and
eliminate it, for example, to adjust the
inlet deflector. When abrasion of the
whole unit reaches a certain degree,
replace it.
3. During replacement of the air flow grid
plate, the design requirement should be
satisfied. Determine whether to replace
or how to replace by air flow distribution
test.
Test and criteria as well as
standard refer to
GB/T1393-92 [ESP
Performance Test Procedure].
(IV) Maintenance
of ESP top
1. Check and repair any abrasion,
corrosion or air leakage on the ESP top.
2. Check rainwater collecting annulus
and downcomer.

(V) Outside
insulation and
frame cover
maintenance

1. Check outside insulation and frame
cover for any falling off or damage and
carry out treatment.
2. Check the corrosion and fixation of
the outer frame cover. Measure should
be take for any loose or abrasion.
3. Water flow direction should be taken
into consideration when lap the new
plates to the old plates and the lapping
seams should be straight.
Outer insulation and frame
cover should be plain, firm,
orderly, rain-tight and
anti-gale after maintenance.
(VI) Outlet smoke
chamber
maintenance
1. Maintenance of the outlet smoke
chamber refers to that of inlet smoke
chamber maintenance.
2 maintenance of the trough plate:
1) Check abrasion and deformation of
the trough plate and correct them.
2) Check and reinforce the support,
suspension and arrangement of the
trough plate.
3) Trough plate rapping mechanism

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maintenance refers to anode rapping.
(VII) Maintenance
of manhole
1. The opening and closing of the
manhole is free and airtight without air
leakage (check it based on the air
leakage during equipment operation),
replace disable packing seal and
corrosion, damaged bolt and nut.
2. Check corrosion of the inner wall of
the manhole and carry out rescaling and
repairing.
3. Check safety signs on the manhole,
which should be complete.
The opening and closing of
the manhole is free with
complete safety signs without
air leakage.
6.3.5 ESP ash hopper and slide damper
Maintenance of
ash hopper and
slide damper

1. Check corrosion of flange contacting
surface of the ash hopper based on the
leakage and corrosion during operation.
Repair as required and grind the welding
points with sand grinder.
2. Check the arch plate on ash hopper
for any sealingoff with the side wall. The
surface should be smooth and flat
without scar after repair welding.
3. Check the abrasion and fixation of the
supports in ash hopper and hanging
beam of the air baffle of ash hopper.
Repair, correct and weld any
displacement.
4. Check abrasion, deformation and
loose of the air baffle in ash hopper;
check abrasion of the lug and
suspension ring of the turning parts of air
baffle; repair and replace as required.
5. Maintenance of the slide damper at
the bottom of ash hopper: replace gland
packing at slide damper and ash hopper
flange to eliminate the ash leaking points
at contacting surface. Check the
Inner wall of the ash hopper is
free of leakage and cicatricle,
which may catch ash.

Corners in ash hopper are
smooth without dead angle.

Ash hopper is free of
deformation and the supports
structure is secured.

Air baffle is free of loose and
inclination. Replace the
hanging ring if the abrasion
volume is greater than1/3 of
its body.
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operation of the slide plate mechanism
for any seizing; adjust them and remove
rust as well as add lube oil.
6. Ash hopper gasification unit
maintenance:
(1) Check gasification pipe line and
gasification electric heater.
(2) Check abrasion and blockage of the
ash hopper gasification plate and
replace them when manufacturer limit is
exceeded.

Valves should be opened and
closed freely and can be
reliably isolated without
leakage.

Stairs, platform ,
rail maintenance
1. Check all platforms, passages, stairs
and rails inside and outside ESP; repair
and replace those damaged or not
conform to safety regulations.
2. Remove rust of outdoors steel
structure, such as platform, passage,
stairs, rail, reducer casing and paint.
There should be no crackle or
corrosion; the footpath on
platform is straight and flat.
Strength meets requirements.
6.4 Tests after ESP maintenance
6.4.1 Prerequisite for acceptance test
1. Tests and commissioning on the ESP HV/LP electrical equipment have completed.
2. ESP mechanical maintenance has completed and test of turning equipment have
finished.
6.4.2 Acceptance test items
It is to verify the maintenance quality of ESP mechanical parts and electrical parts and ESP
performance.
Cold state acceptance and test
1. Spot-check of distance of two different electrodes:
(1) Record the distance of two different electrodes detect during maintenance. spot-check
and review 5%~10% of them.
(2) Select 1 or 2 passages which are recorded to detect the distance of two different
electrodes. The result should be in accordance with the requirement on distance of two different
electrodes. Repair and detect the electric field which fails to meet the requirements.
2. Air flow distribution test: for ESP passed model test with a similar condition with tested
equipment, air flow distribution test will not be performed during overhaul. Air flow distribution
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test can be carried out in one of the following cases:
(1) Air flow grid plate is over worn; it is needed to or has significantly adjusted or replaced
the inlet deflector and air flow grid plate.
(2) Dedusting efficiency drops significantly and operation condition of ESP changes
significantly; the air flow uniformity is doubted to meet requirement.
Air flow distribution test refers to GB/T13931-92 [ESP Performance Test Procedure]. If the
test results can not meet the standard, calculate and adjust again until requirements are
satisfied.
3) Rapping acceleration test: when serious ash accumulation exists on the electrode wire
and electrode plate, rapping acceleration test should be considered to be performed. Test
should be carried out as per GB/T 13931-92. When design requirements of manufacturer can
not be satisfied, cause should be found out and treated.

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7. Double screw rod air compressor(zrseries)
7. 1 Double screw rod air compressor technical specifications
ATLAS COPCO fixed type air compressorzr series is a kind of oil spout double screw rod
air compressor. This type of air compressor is of the following advantages ,such as, structure is
simple, can be operated easily, the number of wearing parts is few, changing spare parts is
easy and function is Stable and reliable. Therefore it is widely used in many related industries.
7. 2 Double screw air compressor structure
ZR110 to ZR750 air compressors are oil-jet twin screw stem types with two stages
compressing and driven by motor. They can provide air with stable pressure. Water cooling is
adopted. For this kind of air compressor, their structure and operation principle are nearly the
same although there are some differences in details. Air compressor is installed in a noise
enclosure including the following parts:
air filter
-LP screw stem head
-intermediate cooler
-hpscrew stem head
aftercooler
motor
Driving coupling
Gear box
-Elektronikon. Control system
Safety valve
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Front elevation of ZR series air compressor
AF. Air filter
AO. Air outlet
Ca. Aftercooler
Co. Oil cooler
CM. Elektronikon PC controller
Daa. Automatic condensate blowdown port of aftercooler
Dai. Automatic condensate blowdown port of Intermediate cooler
Dma. Installation port for condensate manual blowdown valve of aftercooler
Dmi. Installation port for condensate manual blowdown valve of intermediate cooler
Dra. Aftercooler condensate blowdown tank
Dri. Intermediate cooler condensate blowdown tank
Eh. Hpscrew stem head
El. Lpscrew stem head
M1. Main motor
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Svh. Hpsafety valve
Svl. Lpsafety valve
TV. Full load/no-load valve
WI. Cooling water inlet
WO. Cooling water outlet
1. Direction of motor rotation
2. Flange
3. Maintenance hole for air filter
4. Regeneration air pipe with non return valve

Side elevation of ZR series air compressor
AF. Air filter
AO. Air outlet
Ca. Aftercooler
Ci. Intermediate cooler
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DP2/5. Blowdown plug screw (painted green)
Dra. Aftercooler condensate blowdown tank
Dri. Intermediate cooler condensate blowdown tank
Eh. HP screw stem head
El. LP screw stem head
M1. Main motor
Svh. HP relieve valve
Svl. LP relieve valve
TV. Full load/no-load valve
WI. Cooling water inlet
WO. Cooling water outlet
Y1. Loading solenoid valve
1. Direction of motor rotation
2. Flange
3. MD dryer joint
4. Cap
1. Drive system: includes main motor, coupling, gear box etc. Normally, the application of
coupling is ignored for minor units. For medium or large units, separable coupling drivers
will be installed for easy assembling and maintenance.
2. Major equipment: in the shape casing, two engaged screw stem rotors are arranged
parallelly, respectively called female and male rotor. Two rotors form a pair of enclosed V
type space with casing. This space will reduce along with the rotation of rotor and the
space will move towards primary port from intake port. This is the whole process of intake-
compress - primary.
3. Control system includes induction system, governor system, minimum pressure valve bank,
safety control system and PC controller. Subsystems all contain associated solenoid
valves, sensors, air-operating piping and related PC programs and orders.
Control system contains the most parts and acts most frequent. Therefore, it is the system
with the most failures. The largest differences and features of different brands are reflected by
this system. In consideration of high reliability, quantity of parts in the ATLAS unit is reduced as
far as possible. Even the governing system is cancelled. Therefore, ATLAS unit has a simple
operation method. In addition, ATLAS combines the load controlling system and discharge
system to the air intake valve. Failure ratio is reduced significantly by adopting piston valve
instead of adjustable butterfly-valve. Its simple operation method makes it difficult for user of
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small amount of air to match demand and supply.
4. Cooling lubrication system: includes special lube oil, heat exchanger, temperature- sensing
valve, oil cut-off valve and cooling fan.
5. Air flow-oil system-cooling system: air is sucked into LP head (E1) through air filter;
after compression, compressed air enters intermediate cooler (Ci) to be cooled. Then
compressed air enters HP head for further compression. Before enters air network, it flows
through silencer (AS) to reduce noise and aftercooler to be cooled. A check valve (CV) is
also installed at the downstream of silencer for ZR110-275 and downstream of aftercooler
for ZR300-750.
6. Condensate blowdown system: two Water separators are installed. One is installed at the
down stream of intermediate cooler (mti) to prevent condensate from entering HP screw
stem head. The other is installed at the down stream of aftercooler to prevent condensate
from entering primary air pipe. Water separator is connected to the condensate blow down
tank. Each blow down tank is equipped with a ball float valve for automatic blowdown and a
manual blowdown valve. For ZR300-750, an extra water separator is installed on the vent
pipe preventing condensate from entering silencer when equipment transfers from loading
to unloading.
7. Lube oil system: lube oil in the oil sink of gear box is pumped by the oil pump (OP) to
bearing and synchronizing gear through cooler (Co) oil filter (OF). Bypass valve (BV) will
open when pressure of lube oil reaches the setting valve.
Cooling system: cooling water flows by cooler (CO) to the cooling water jackets of HP screw
stem head (Eh) and LP screw stem head (El) respectively. For ZR300-750 type, cooling water
is also used to cool the vent pipe of LP screw stem head (E1) and flows by Intermediate cooler
(Ci) and aftercooler (Ca). Cooling system parts failure will directly result in outage of unit.
More than 90% of heat exchanging is carried by cooling system. During hot days, volume of
exchanged heat will increase several times. Any improper maintenance of the cooling system
will result in poor operation, low efficiency, high energy consumption etc. It is important to
perform preventive maintenance before hot days.
7. 3 Maintenance level for Double screw air compressor
The maintenance level of the air system is determined by the oil service life, action times of
parts, bearing service life and abrasion situation of parts..
Normally, the quality and performance of the mineral oil will significantly decrease after 2000
hours operation, and the accumulated carbon will increase. After 2000 hours operation, the
meshes of the filter adopting paper element will be seriously blocked causing the filtering
efficincy decrease, pressure of the lube oil decrease and the inactive power of the unit increase.
The service life of the oil used for filter with glass fibre as element will reach more than 4000
hours. In addition, the service life of the sealing rings of the moving parts in the minimum
pressure valve, load controlling valve of the control system might reach 4000hours because of
iron-oxygen used in the sealing ring. Normally, service life of the air compressor is about 8000
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hours. The maintenance can be divided into three levels: A, B and C corresponding to
2000,4000 and 8000 hours. At the above said time and their times, maintenace should be
carried out to prevent accident. Details include:
Quarterly: level A: oil, oil filter, air filter
Half a year: Level B: Level A plus oil conten as well as maintenance packages of control
system.
Yearly Level C: Level B plus temperature control valve, loading solenoid valve, oil pressure
control valve and operation of motors.
After several yearsoperation, dynamic balance and strength of resonance of the air
compressor should be tested to provide data for overhaul of the main machines and driving
system.
. 4 Level C maintenance for double screw rod air compressor
7.4.1 maintenance preparation:
Start the equpment to run for 15minutes; estamite the operation situation of the equipment via
primary observation so as to determiine the keypoints of maintenance activity and to increase
lube oil temperature and decrease its viscosity.
Verify operating parameters of the unit by PC controller for comparision with data after
maintenance;
Shutdown procedure: close outlet valve, cut off the power supply of the unit and push
emergency shutdown button;
Open manual blowdown valve, vent down the pressure of the primary pipe; verify pressure of
entire unit and close the waterinlet/outlet valve.
Site preparation: level C maintenance will break down all system parts except main machines
and replace all oil. Therefore, the worinf area should be treated to avoid pollution and be good
to clean site.
7.4. 2 Dismantling of unit system parts:
Turn loose by wrench the oil drain hole screws of the oil and gas bucket, oil filter seat, mian
primary pipe,oil cooler, oil cut-off valve and gear box; when completely empty lube oil and vent
the oil cutoff valve and main primary pipe, plain screw driver should be used to drive clockwise
the machine from the motor rod wheel to ensure lube oil in the main machine and gear box is
completely drained out. Waste oil should be treated intensively to avoid pollutions.
Manually take off the set screws (8) at the ends of main primary pipe between the oil and gas
bucket cap and cooler; check two sides of the sealing ring and store them caerfully.
Remove by wrench the connecting hoses of pressure difference transmitter, drain pipe, main
control hoses, oil return hoses, main oil return pipe and HP oil pipe before and after cooler.
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Remove by wrench the set screws (6) of the minimum pressure valve and remove minimum
pressure valve and lower check valve.
Remove set screws on the oil separator cap with wrench, after remove all screws, tighten
screws on the cap side and completely separate the cap from the oil and gas bucket and turn it
in clockwise direction to the final position. Take out oil content element and upper/lower sealing
rings and well store them.
Loose set screws (4) of the oil pressure ontrol valve+temperature control valve with allen
wrench to take off oil pressure regulator; then take pout the disc of temperature control valve
and well store them.
Remove oil filter(3) with chain wrench.
Remove set screws (8)oil cut valve with wrench, and take off oil cut off valve assembly(2).
Remove set screws (8) of air inlet valve wrench and take off air inlet valve assembly(2).
Loose holding screws (2) of the air filter and take out air filter element(2).
7.4.3 Dismantling of minimum pressure valve, oil cutoff valve, air inlet valve and oil pressure
regulator
1. Dismantle minimum pressure valve assembly: loose set screws of the minimum pressure
valve cap, and take out reset spring; slightly knock the piston from outside to inside to let it
fall down automatically. Pry out sealing ring with plain screw driver. Remove set screws (3 )
of the check valve packing seal and take off packing seal and triangle gasket. All parts
should be well stored
Dismantle oil cutoff valve assembly: remove inner snap ring with inner snap ring pliers. Take out
piston and reset spring. Remove set screws (4) of the lower end cover with wrench and take
off the end cover. Take out piston. All parts should be well stored.
Dismantle oil pressure valve regulator assembly: loose the seat and set screws of the oil
pressure regulator with allen wrench to take out piston
Dismantle air inlet valve assembly: remove set screws (4) of the end cover of air inlet valve with
wrench to take out reset spring. Knovk the piston from outside to inside until it drops naturally
pry out the sealing ring of piston and take out the snap ring of the end cover of load controlling
valve with inner snap ring pliers. Clamp the end of the end cover with lock wrench. Pull out
end cover by slightly turning it. Then take out reset spring. Pull out load controlling piston with
vise.
Dismantling of all parts are completed up till now.
7.4.4 Check, verify, repair, replace system parts
In turn check sealing ring of parts.
In turn check operation of pistons of parts.
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In turn check abrasion of wearing auxiliary parts.
In turn check aging of all hoses
Verify the above check activities. Replace the entire maintenance package containing parts
needed to be replaced and record the results.
7.4.5 washaftercooler:
Remove holding screws of the water inlet and outlet chuck of the aftercooler with wrench. Take
out chuck. Lift the entire aftercooler to a specified location.
Marinate the water pipes and oil pipes with scale washing agent and carbon washing agent for
6 hours, nd flush with clean water. Determine whether to marinate the pipe based on the
washing result.
7.4.6 Check sensors
Check all wire connecting terminals inside the electric cabinet and the strength of the
connecting wires.
Check ablation of main contactor.
7.4.7 Recover
Recover chucks of cooler and water pipe.
Recover the system parts according to the turns of parts, assembly and system which is
opposite to the dismantling of the system
7.4.8 Startup commissioning:
Check and verify all hosesconnection, tightness of all holding screws;
Open outlet valve to test pressure; the minimum pressure valve is free of leakage;
Open cooling water valve and no leakage is detected;
All screws of the oil drain holes, fill cooling oil to the specified level and then tighten the oil filling
screw;
The unit and reset all maintenance parameters;
Unit without abnormal condition; load the unit without abnormal condition;
Unit, fill oil to the level of oil filling port and tighten the oil filling screw;
The unit and load; verify all operataing parameters meet the requirements

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8 Oil Free Screw Air Compressor
8.1 Technical Specifications
To supply clean compressed air, the motors supply no lubrication and cooling to the
compressing part of the main rotor. The motors adopt two stage compressions, two stage
cooling and two stage gas water separation to lower the work temperature to an acceptable
level. The rotors are made of special materials with advanced technology to lower the motor
load. All the above is to make the air compressor adapt to harsh work conditions. However, the
parts with no compressed air contact, including gear box and bearings, are still oil lubricated
and cooled.
8.2 Oil Free Screw Air Compressor Configuration
The compressor consists of driving system, two stage air intake valve, low pressure motor,
high pressure motor, gas water separator, cooling system, lubrication system and electronic
control system.
As the compressor has twin motors, the driving system and working principle is different
from those with single motor.
When the compressor starts, it drives the specialized gear box through coupling, which at
the same time drives the twin motors and oil pump to pump the oil from the gear box. In order to
prevent oil leak to the rotor from the motor casing when the pressure is high, the oil system has
a by-pass valve, which opens automatically to release the pressure. When the compressor
reaches the nominal speed, the solenoid valve is triggered. The primary airintake valve
gradually opens under the system pressure to start the primary motor. The primary motor works
and the compressed air enters the middle cooler. With pressure increasing, the high pressure
air overpowers pressure relief valve to completely open the airintake valve, followed by
pressure increase and primary gas water separator to enter the secondary air intake valve
silencer to open the minimum pressure valve to go to the secondary motor for further
compression. The high temperature and pressure gas is supplied after secondary oil gas
separator and cooling. When the secondary pressure reaches relief pressure, the loading
solenoid valve is cut off and turned off to release the valve and the pressure is released with
primary airintake valve closed and secondary airintake valve returned, the motor starts
unloading. Simultaneously, the oil from the oil pump is supplied to the dual motors and gears
after filtering and the oil returned is collected by the gear box after oil cooler and the balanced
between the oil and the atmosphere is maintained through breather.
If the unloading is too long, the controller will stop the compressor until the pressure drops
to loading pressure to initiate another cycle.
8.3 Maintenance and Service
1. It shall be carried out by professionals.
2. Daily monitors the operational parameters.
3. Weekly cleans the motors.
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4. Monthly monitoring of the oil consumption.
5. Cleans or replaces the air filter and oil filter every 2000 hours.
6. Cleans middle cooler, rear cooler, oil cooler, oil breather, gas oil separator every 4000
hours and carry out motor lubrication.
7. Replaces lubrication oil every 8000 hours.
8. Overhual the motors every 16000 to 20000 hours.
Content:
1) Above 1 to 7.
2) Examine and replace main motor bearings.
3) Examine and replace motor bearings of fan.
4) Replace gear box bearing.
5) Observe oil pump and by pass valve.
6) Examine main motor.
8.4 Commissioning
1. Check all the pipes are well connected, nuts tightened.
2. Open the outlet valve to test the pressure and make sure there is no leakage from the
minimum pressure valve.
3. Power supply to the motors and reset all the service parameters;
4. Start the compressor with no abnormities noticed and loading goes well;
5. Restart the compressor and load to ensure all the parameters are in compliance to the
requirements.
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9 Refrigerated Air Dryer
9.1 RSL Type Refrigerated Air Dryer Technical Specifications
9.1.1 Working Principle Description
RSL Type refrigerated air dryer lowers the air temperature so that the water vapor in the
compressed air become over-saturated and turns into water droplets, which will be separated
and discharged, so that the compressed air can be dried. The dew point of the compressed air
in the RSL dryer can be lowered to 2~10 under pressure.
RSL Type refrigerated air dryer product is as a result of several new technical innovations
and patents, characterized by its stability, efficiency, cost-effectiveness and automation.
9.1.2 Refer to Figure 1 for the work procedure of the refrigerated air dryer.
Y
S
3
PT PT
Y
S
1
YS2
R
S1
R3
Y
S
1
R
KP15

12
5
6
8
3
2
10
9
11
1
R5
DN15
DN15
T
R5
T
T
T
YS2
D
N
1
5
D
N
1
5
X1
7
D2
4
D1

Figure 1 Work Principle of the Refrigerated Air Dryer
1. Pre-cooler 2. Evaporator
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3. Cyclone Separator 4 Automatic Water Capacity Adjustment Valve Discharge
Equipment
5. Refrigeration Compressor 6. Condenser
7. Water Regulating Valve 8. Drying and Filtering Device
9. Stop Valve 10. Expansion Valve
11. Capacity Adjustment Valve 12. High/Low Pressure Controller
9.1.3 Process Description
Air Compression
1. Air compression consists of pre cooler, evaporator, cyclone separator, and automatic
water discharge equipment.
2. The humid compressed air from the air compressor enters the pre cooler of the
refrigerated air dryer, where it conducts heat exchange with the low temperature
compressed air from the cyclone separator and becomes cooler. As a result, it is
condensed due to over saturation together with oil and dust particles.
3. The pre-cooled compressed air enters the evaporator to carry out a further strong heat
exchange, when the temperature is dramatically dropped to the dew point to produce
large quantity of water, which will then be drained together with that in the pre cooler
by the automatic water discharge system.
4. Then, the low temperature compressed air enters the cyclone separator, where the
condensed water particles is separated by enforced cyclone and discharged. By now,
the compressed air reaches the drying requirements.
5. The dried low temperature compressed air returns to the pre cooler to heat exchange
with the humid high temperature air, which is then to be conveyed downstream for
use.
Refrigeration System
1. The refrigeration system mainly consists of air compressor, condenser, expansion
valve and evaporator with other auxiliary parts.
2. The refrigerant is compressed by the refrigeration compressor into high temperature
and pressure gas and output into condenser, where it is cooled into liquid with normal
temperature and pressure. Then it goes to expansion valve and expands and changes
into low temperature and pressure gas liquid mixture and enters the evaporator to
heat exchange with the compressed air. The refrigerant mixture absorbs the heat from
the incoming compressed air and evaporates and is sucked into the refrigeration
compressor to reinitiate the cycle.
3. The hot air bypass valve is to control the amount of refrigerant to be recycled based on
the load change of the compressed air so that refrigeration system matches to the
load of the compressed air to ensure the quality of the air. The valve requires manual
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adjustment when the load varies greatly.
4. The high/low pressure controller is to ensure the refrigeration compressor work within
the specified scope. The condensation controller is to ensure the condensation
pressure not lower than specifications. Both the scope and the condensation pressure
have been factory pre-set.
5. The drying and filtering device plays the role of cleaner, to remove the water,
impurities, and acid matters in the refrigerant.
6. The water regulating valve is to control the water supply based on the primary
pressure of the refrigeration compressor to maintain the normal condensation
pressure. The valve requires manual adjustment when the compressed air load varies
greatly or the temperature and pressure of the cooling water varies dramatically.
7. Refrigerant valve is to fill in refrigerant when the dryer is being assembled or serviced.
8. The solenoid valve is to cut off the high and low pressure parts of the refrigeration
system when the dryer stops, so a balance between them can be gradually achieved.
9. The stop valve is for maintenance and service.
9.2 Maintenance and Service
9.2.1 Principles
1. The dryer has to be enlisted for company assets management, and the maintenance,
service and operation log regulations need to be set up based on the characteristics of
the dryer and to be strictly implemented.
2. The operation, maintenance and service of the dryer shall be conducted by trained
personnel.
3. The dryer in operation needs to be checked regularly, every 1 to 2 hours, and logged.
9.2.2 Content
1. Periodically check the conditions of the dryer to ensure the its good performance.
Recommended once weekly.
2. Cleans the automatic water discharge system periodically to remove the accumulated
oil and impurities that might affect its normal operation. Recommended once weekly.
3. Clean the blades of the fan condenser once every two weeks to remove the dust and
impurities. The procedures is as follows as indicated:
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Note: Care shall be taken in operation not to damage the blades and heat exchanger. Striking
from hard objects is prohibited.
9.2.3 RSL Air Dryer Troubleshooting
Table 5 Air Dryer Troubleshooting
Conditions Possible Causes Solutions
Power supply or power fault Check the power switch or the lines
low voltage
Check voltage to make sure it complies
with requirement
Loose power connection to
the electronic control
system
Reconnection
Electric trip
Check the breaker and thermorelay and
reset. Also examine the voltage and
power lines
Delayed start after high/low
pressure protection initiates
Wait after the delay to start
Refrigeration compressor
damage
*replace compressor
Refrigerant leakage
*Check, and repair the refrigeration
system and refill in refrigerant
The dryer
does not
start.
start up capacitor damage
Replace capacitor
Clogged water drain system Clean, repair or replace
Installation error in automatic
water drain system
Reinstallation
Humid air
from the
dryer outlet
Air by-pass valve not turned
off
Turn off the by-pass valve
Condenser cleaning of the air-cooled air dryer
IN OUT
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The air dryer does not work Check the air dryer system
The front service valve of the
automatic drain system is not
turned on
Turn on the front service valve
Refrigeration system faulty *Check or repair the refrigeration system
Poor condensation capacity Clean or dust condenser
Air compressor
overload(exceed the rated
capacity)
Reduce the capacity or replace air dryer
Compressed airintake
temperature too high
Lower airintake temperature or replace air
dryer
Compressed airintake
pressure too low
Increase airintake pressure or replace air
dryer
Cooling water temperature
too high
Lower cooling water temperature
Amount of cooling water not
enough
Adjust water regulating valve or increase
water supply
Ambient temperature too
high(Wind-cooling type)
Improve site ventilation or replace with a
water-cooling air dryer
Hot air by-pass valve opened
too wide
Reduce the opening
Heat expansion valve
opened too small
*Increase the heat expansion valve
Refrigerant not enough *Add refrigerant
Refrigerant leakage *Service the refrigeration system
Abnormal
dewpoint
Clogged drying and filtering
device
*Replacement
Clogged or damaged Cleaning or replacing
Service valve not open Open service valve
Float Type
Automatic
Water
Discharge
system
faulty
Installation error Reinstall
Solenoid valve no power Check the cables to supply power
Solenoid coil burnt Replace solenoid coil
Electronic
Automatic
Discharge
System
Faulty
Clogged valve Cleaning
Air Dryer
Poor condensation Clean condenser
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Air dryer overload
Check whether the flowrate, temperature
and pressure of the compressed air are
within the rated values
Cooling water too hot Lower the temperature of cooling water
Cooling water not enough
Adjust water regulating valve to increase
water
high(air cooling type air
dryer)
Improve ventilation or replace with water
cooling type air dryer
Condensation motor faulty *replace motor
Clogged cooling system
*Check the drying and filtering device and
heat expansion valve, either replace or
repair
Thermo-sensor of the heat
expansion valve faulty
*Replace the expansion valve
stops after
operation or
frequently
trips during
operation
Air existing in the
refrigeration system
*Re-vacuumize and refill in the refrigerant
The voltage exceeds the
rated voltage scope
Check the power voltage
Electronic
protective
switch
tripping
overloaded
Adjust the air drying system
Poor condensation Clean the condenser
The air dryer overloaded
Check whether the flowrate, temperature,
temperature and pressure of the
compressed air are within the rated scope
Cooling water too hot Lower cooling water temperature
Cooling water not enough
Adjust water regulating valve and increase
water amount
high(air-cooling type air
dryer)
Improve ventilation or replace with water
cooling type air dryer
Refrigeratio
n
compressor
temperature
too high
Refrigerant too little Fill in refrigerant
Frost at the
surface of
refrigeration
compressor
The air dryer was less
loaded
Adjust hot gas by-pass valve or adjust
water regulating valve or to adjust the load
of the air dryer
The air inlet and outlet
valves are not fully open
Fully open the valves
Pressure
difference
too high
between the
air inlet and
The amount of compressed
air exceeds the rated amount
Reduce compressed air amount
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air outlet of
the air dryer
Evaporator clogged by ice Adjust refrigeration system
Note: the items with asteroid means they shall be handled by professionals by the
equipment supplier.
Warning: Specified procedures have to be followed in case of faults to prevent further
damage.
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10 Gasification Blower
10.1 Technical Specifications
Type of the blower: SRD-100; Intake flow rate: 11.7m
3
/min; Inlet pressure : 101.3Kpaoutlet
pressure: 199.3Kpa; rotation speed: 1450rpm; motor type: Y225S-4; power: 37KW
10.1.1 Working Principle
SRD-100 Roots blower is a volume type power machine with two impellers rotating in
opposite directions driven by a pair of synchronized gears. Through the two impellers gearing
with each other (clearance between impellers without contact), the inlet and the primary outlet
is divided and the air is transferred to the primary outlet without compression. The air when
reaching the primary outlet is compressed to transfer to the system due to the compressed air
at the outlet side.

Work Principle Illustration
Chinese English
Inlet
Exhaust
10.1.2 Motor Configuration Diagram
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10.1.2.1 Casing and walling
The casing and walling of the blower is an integrated structure made of high strength cast
iron and the casing is horizontal with external side strengthened with bars.
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The walling (with side plates) is installed at both sides of the casing. The side plates
functions to position the walling, and with walling and casing together, they form a sealed
cylinder.
10.1.2.2 Impellers
The impellers are made of quality cast iron with cycloidal profile. The top of the impellers
have wide arch boss, made by specialized lathe. The impellers are fitted to the shaft using heat
expansion methods and through dynamic poise to reach an accuracy of G5.6 in the balance.
10.1.2.3 Gears
Gears are one of the most important parts in roots blower, made of quality chrome
molybdenum steel, and ground by grinder after carburizing and quenching, with a grade 5 in
GB10095.2-2001.
The gears have wide tooth width with good meshing inside the gear box. The deviation
caused by wear can be eliminated by the adjustable gear. Please note that the adjustable gear
and the hub shall not be separated when dismantling but not in adjustment.
10.1.2.4 Bearings
All bearings are E grade with 4 bearings installed on the bearing seat of the walling, among
which the inlet side two bearings performs the role of adjustment and fixing the axial clearance
of impellers.
10.1.2.5 Shaft Sealing
The sealing of the shaft adopts labyrinth seal and at the bottom of the 4 bearing seats is
fixed with V type seal to further separate the oil and gas. In the shaft gland, the seal adopts
rubber structure to prevent oil leakage and dust.
10.1.2.6 Lubrication
The lubrication of the blower integrates splash lubrication and forced circulation lubrication.
The gear box and oil box have all got oil gauge with the correct oil level indicated when the
machine is not operation. In operation, the oil level shall be within the correct level. If the oil
level is too high, the temperature might rise and if too low, the lubrication is not good.
If the blower is used for general purpose, the lubrication oil is mineral oil, such as machine
oil, gear oil, hydraulic oil, or anti-rust turbine oil. There shall be no water, carbonate, resin or bar
contained in the oil. The oil volume in the gear box shall be 2.4 L and in the standby oil box 1.1
L.
10.1.2.7 Cooling system
Cooling water rate: 8~10l/min; Water pressure: 196~294kPa; Inlet water temperature:
Less than 33 .
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10.2 Maintenance and service of the blower can be as per the table below.
No. Period
of

Inspection
Items
Before
Operation
Daily
Three
Months
Annually
Two
Years
Four
Years
Remark
1 Clean the
foreign
objects in the
piping

2 Check every
connection
part
Blower,
piping
3 Valve
operation

4 Inverted
Valve
operation

5 Electric circuit
6 Gear oil
volume
Oil gauge
7 Oil leakage
8 Rotation
direction
As indicated
9 Pressure Pressure
gauge,
vacuum
gauge
10 Safety Valve
11 Current and
Voltage
Ammeter,
Voltmeter
12 Flowrate
13 Noise Gear
abnormal
noise, rotor
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collision
noise
14 Vibration
15 Temperature Ambient,
blower, and
motor
16 Tension and
wear of
V-belt
Adjust if
loose and
replace if
worn
17 Gear and
bearing
operation
Beware of
abnormal
noise
18 Gear oil
replacement
Replace
all(first
replacement
after 500
operation
hours)
19 V-belt
replacement

20 Filter cleaning
21 Oil seal
replacement

22 Rotor and
casing inside
cleaning

23 Gear
checking

10.2.1 Dismantling
1.1 Cautions
1. All the connections and couplings shall be marked.
2. No damage shall be done to the parts especially to the joint surface.
3. All gaskets shall be measured when dismantling.
4. The parts after dismantling shall be kept dust free.
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5. Appropriate dismantling tools shall be used.
1.2 Dismantling Procedure
All the accessories dismantled; discharge the oil in the gear box and standby oil box;
dismantle the wheel; dismantle standby oil box; dismantle gear box and gears; dismantle
walling.
NOTE: In the operation, care shall be taken to protect the seal and bearing internals.
10.2.2 Assembling
2.1 Cautions
1. Check whether the dismantled parts are damaged. Care shall be taken to the joint
surface. When there is damage, repair it or replace.
2. The bearing shall be cleaned first, then greased. When installing, the tools and hand
shall be cleaned first.
3. The joint surface shall be cleaned first before greasing.
4. In case of damage of sealant, then the gasket with the same thickness and quality
material shall be used.
2.2 Assembling Procedure
1. Install the walling (with side plates) of the motor side to the casing.
2. Install the impellers from the gear side.
3. Install walling (with side plates) at the gear side to the casing. Care shall be taken to
the axial clearance. When there is not enough, then, a casing seal can be chosen.
4. Assemble the seal jacket, V shape seal, bearing seat and front and rear bearings. Use
the bearing seat gasket to control the axial clearance.
5. Assemble gears. On both sides of the key sprayed molybdenum disulfide (not on the
gearing face), use the adjustable gear to adjust the impellers and then tighten them
with locknuts.
6. Assemble gear box.
7. Assemble standby oil box. If necessary, the location pin for the standby oil box and
walling shall be remade and implemented.
8. Assemble the wheel and other accessories.
2.3 Clearance Adjustment
The key to the blower assembling is to ensure the working clearance within the specified
scope so its quality and performance is guaranteed. The clearance scope is as follows:
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Clearance as illustrated
Blower Clearance(Reference Value) Unit of Measurement: mm
impellers-casing Impeller-Impeller
Impeller-Front
wall
Impeller-Rear
Wall
Value
Type
a(a1,a2,a3) b(b1,b2) c d
SRD-100 0.16~0.45 0.15~0.27 0.20~0.25 0.20~0.25
1. The adjustment of the casing-impeller clearance(a1,a2,a3) is guaranteed by the
accuracy of the joint accuracy of the casing and walling. No damage shall be done to
the casing and walling.
2. The adjustment of the impeller-impeller clearance (b1,b2): rotate the impellers to the
position as indicated in c. Make sure the driven gear is aligned to the driving gear and
mark it on the shaft. Then install according to order of the gear retaining ring, retaining
gasket, locknut and slightly tighten the nut. Loosen the gear ring to tighten the bolts
and adjust the ring so the impeller-impeller clearance is within the scope. Then tighten
the bolts.
3. The adjustment of the impeller-side walling axial clearance(cd): before installing the
walling, the axial total clearance C+D (through the adjustment of the casing
gasket)need to be ensured. Then through the adjustment of the front bearing gasket to
ensure the c and d distribution.
2.4 Installation of the Transmission Parts
!
Warning: Use appropriate tools to install the wheel on the shaft and motor.
Hammer is prohibited when installing the wheel or coupling.
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2.4.1 Belt Installation
The belt for the blower is narrow V shaped belt. The correction installation of the wheel and
belt will directly affect the life span of the belt and the equipment performance. Following items
needs to be taken care of:
1. Before belt installation, loosen the motor tightening bolts and track adjustable screw to
shorten the central distance. No prying force shall be used.
2. The belt and grooves shall be free from impurities.
3. In consideration of the preliminary elongation rate, after adjustment, the blower can be
operated for 2 hours to ensure the tension. The tension is to ensure no slipping and no
tightness. The tension can be measured by the sagging distance when there is a
weight. Refer to the following illustration.

The fixed force W vertically works onto the central of the belt, when the sagging satisfies
S=0.016a (mm), it indicates the tension is proper. The W is valued in the scope 76.4~101.9N,
with median value as the appropriate.
!
Warning: If the belt is too tight, the lifespan of the belt and bearing will be
shortened. If too loose, slipping and vibration will be caused.
4. Use ruler or lines to check the position of the wheels. As the following diagram
indicates, the axial lines shall be parallel after adjustment. The symmetrical plane of
the corresponding grooves shall be overlapped, with deviation of 20l1.6a/1000.
5. After adjustment, the coupling bolts and track adjustable screw must have been
tightened.
6. When replacing belt, belts of the same specifications must be used and old and new
ones shall not be mixed. Upon wheel replacement, the wheel shall be the same as the
previous specifications.
7. Loosen the belts if they are not used for a long time.
!
Warning: In order to ensure safety and security, belt hood shall be installed.
2.5 Safety Valve and Check Valve
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2.5.1 Introduction
1. Cautions

1) The safety valve for the blower is metal sealing type with the seat and core
assembled together after grinding; therefore, it is not affected by ambient humidity
and temperature. If there are foreign objects attached to the seat, when the core
works, it will go to the contact surface, causing leakage. In addition, when moving
the valves, it shall be handled carefully as collision will cause leakage.

2) The safety valve must be installed on an horizontal pipe through a tee to ensure
the axis of it is vertical to the ground.
3) During operation, if the sensitivity of the safety valve is lowered, then it means
immediate cleaning to the valve seat and core. The method is to remove the cap
and spring and use diesel or petrol to clean it. (The following diagram indicates
the structure of the valve.)

A27TW-2Q SVF Type Safety Valve(Thread Type)
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1. Adjusting Bolt 2. Locknut 3. Cap 4. Valve seat
4) All the parts shall be periodically cleaned in order to ensure the life span and its
sensitivity.
2. Principle: When the load exceeds the set pressure of the safety valve, the valve opens
to prevent blower faults.
!
Warning: When the blower is in operation, do not stay around the primary hole of
the safety valve to prevent getting burnt.
2.5.2 Check valve
The check valve has to be installed onto a horizontal pipe. During installation, the valve
rotation shaft shall be horizontal and pay attention to the flow direction (refer to the diagram
below).
H74W-1C Type Check Valve
Reminder: There shall be plenty of space to ensure the opening and closing of the
valve.
2.6 Troubleshooting
Troubleshooting Table
Faults Causes Solutions
Insufficient air
volume
1. piping leakage
2.Clearance increase
3.inlet clogged
4.belt slipping
1.Check the connections and repair if
there are leakages
2. Adjust gap or replace rotor
3.clean filter
4. Adjust the tension or replace belt.
Motor
overload
1. Inlet resistance too much
2. Pressure increase enlarged
3. Friction between the cylinder and
impellers
4. Speed too high
1.Clean filter
2. Check primary pressure and load
3. Adjust clearance
4. Replace belt wheels
Overheating
1. Pressure increase enlarged
2. Friction between the cylinder and
blades
1. Check the inlet and primary pressure
and load
2. Adjust clearance
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Faults Causes Solutions
3. Lubricants too much or too less
4. Lubricant oil quality not good
3. Check the oil gauge
4. Replace oil
Noise
1. Mislocation of the synchronized
gears and rotors
2.Bearings worn
3.Pressure rise fluctuate widely
4.Gears damaged
5.Safety valve closes and restarts
automatically
5. Check valve damaged
1.Correct the position and get them
tightened.
2.Replace bearing
3.Check the piping and load
4.Replace gears
5.Check whether there is pressure
overload or adjust the safety valve
6.replace check valve
Refuse to
start
1.Primary outlet clogged or valve
refuses to open
2. Power connection wrong or other
electric problems
1. Remove the blockage or open the
valve
2. Check the connection or other
electrics
Lubricant
leakage
1. Oil level too high
2. Seal damaged
1. Lower the oil level
2. Replace seal
Vibration
1. Foundation unfixed
2. Bearing worn
1. Fix the foundation
2. Replace bearing
Reminder: Refer to the manual provided by the motor manufacture for the maintenance
and service of the motor.
10.3 Main Parts and Consumables
10.3.1 List of Main Parts
10.3.1.1 Main Parts List
Driving Impeller
Driven Impeller Sealing Jacket
Name
Type
No. Qty No. Qty No.
Qty
SRD-100 SRD100.1.1 1 SRD100.1.2 1
RD.1-17( )
ARD.1-17( )
2
2
Side Plates Bearing Gear Components
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Name
Type

No. Qty No. Qty No. Qty
SRD-100 RD.1-04 4
NU311/P6
21312
2
2
RD.1-05
RD.1-07
RD.1-08
1
1
1
10.3.2 Consumables
No. Name No. Qty
1 Lock washer 45 GB858-88 2
2 Lock washer 60 GB858-88 2
3 Locknut M45X1.5 RD.1-29 2
4 Round nut M60X2 GB812-88 2
5 Front bearing seat seal gasket RD.1-49 2 sets
6 Rear bearing seat seal gasket RD.1-48 2
7 Casing seal gasket RD.1-40 2
8 Oil box seal gasket RD.1-41 2
9 Structure oil seal B55X78X12 GB9877.1-88 2
10 V belt(with coupling) 5V-1000 3
11
V shaped rubber oil retaining
ring 72X90X5 T08.1 4
12 O ring 55X3.1 GB1235-76 1

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11 Slag Removal System
11.1 Slag Hopper Maintenance and Service
11.1.1 Slag Hopper and Slag Gate Structure
The slag hopper is to temporarily store the furnace slag. The slag from the furnace falls
into the hopper and releases great amount of heat and explodes to many small pieces to
get stored in the hopper. After a period of time, the slag will be flushed out of the hopper by
water through the slag gate and crusher. The water level in the hopper has to be
maintained; therefore there are two 6 inch water inlet pipe and drain pipe in the hopper.
The structure of the hopper is bottom support. The up water trough is located below the
header under the water-cooling wall. The water sealing plate of the header under the
water-cooling wall is connected to the water trough to seal the furnace and ensures the
water wall expansion and contraction to maintain the stability of the water level.
Surrounded the water trough are 10 pieces of 2 inch low pressure water pipe and one
overflow pipe to ensure the water level. The 4 corners of the water trough have 4 discharge
valves which are used when the furnace is being serviced to drain the water and slag in the
water trough. The slag hopper has two halves on the left and right connecting with each
other. At the bottom, it is fitted with slag gate and slag crusher.
Slag Gate Structure
The slag gate consists of gate, seat, guiding track, wheel, wheel shaft and cylinder.
11.1.2 Slag Hopper and Maintenance and Service
Item Working Methods and Cautions Quality Standard
1.
Preparation
1. Open the drain valve to drain the water.
2. Open the slag gate manhole so it is fully
open.
3. Remove the slag on the hopper wall and turn
on the slag crusher to discharge the slag
through manhole.
Cautions: Do not damage the hopper walls
whiling removing the slag. When the slag
crusher turns on, there shall be nobody or tools
in the hopper.

2. Internal
Examination

1. Check on the concrete surface on the
internal wall of the hopper. Repair the broken
part or crack part. Remove the crack before
repair.
2. Slag hopper concrete sleeve replacement
1 Smooth concrete surface
without cracks, breakage
or arching.
2 The concrete surface
after relaying shall
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Item Working Methods and Cautions Quality Standard

shall be after complete removal of the original
concrete walling and the strengthening nails.
3. Flush the water nozzle in the slag hopper
(including observation lens nozzle) and clear
away the slag around the nozzles.
4. Clear and flush the slag in the overflow
outlet and overflow water container.
comply with the
specifications.
3 The nozzles shall be free
from blockage and
ejection distance is
normal.
4 No Slag in the water drain
outlet
3. Water
sealing
Equipment
Examination
and
Clearance

1.Use high pressure water gun to clear away
the slag accumulated in the water trough.
2. Remove the water nozzle in the trough and
turn on the flushing valve to examine and
flush the trough and nozzle and then
re-install.
3. Check the water sealing plate and the bolts
connecting the plate and water cooling walls.
Replace any warped or broken bolts.
4. Check the surface and welding seam of the
tooth shaped dam plate in the water trough
and check the slag metal mesh and the
welding seam with the fixed parts.
5. Measure the clearance between water seal
plate and the bottom of the water trough.

1. No slag, dirt or sand in the
trough. No hindrance in the
expansion of the water
cooling wall.
2. Sealing quality, no leaking
and sealing water level
constant. No blockage in the
flush pipe and nozzle in the
trough.
3. No corrosion, deformation
of the water sealing plate and
the bolts is free from
deformation or breakage.
4. No corrosion from the
tooth shaped overflow plate.
The welding is well done. The
slag metal mesh is free from
deformation, corrosion.
5. The clearance between the
water sealing plate and water
trough complies with the
design requirements.
Slag Gate Maintenance and Service
Items Procedure and Cautions Quality Standards
1.
Dismantling

1. Remove the bolts connecting the slag gate
panel and room and remove the panel.
2. Open the slag gate and to its maximum
opening and turn off the gas/hydraulic
1. The base antifriction plate
shall be worn less than 2mm.
When being replaced, the
head of the bolts shall be
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controller.
3. Remove the nuts for the guiding wheel and
get the wheel out and loosen the bolts for the
wheel shaft to get it out.
4. Remove O shaped ring and clean its
groove.
5. Close the slag gate and in an off position.
6. Remove the nuts between the piston rod
and slag gate and bolts between guiding rod
and slag gate. Separate the piston rod and
slag gate using gas/hydraulic controller.
Then, turn off the controller and cut the power
off.
7. Tighten the piston cylinder using steel wire
and chain lift and then remove the bolts
between the cylinder and piping and cylinder
and slag gate. Remove and separate the
cylinder and slag gate from the equipment.
Cautions: The exposed part of the piston rod
shall be packed and when being lifted, no
striking or collision.
8. Remove the slag gate wedge and put a
jack under the gate so to get the slag gate out
of the guiding track. Tighten the gate and
chain lift with metal wire and get the guiding
track removed.
9. Move the slag gate out of the base slowly
by operating the chain lift.
aligned with the surface.
2. The slag gate is smooth
and without deformation. The
wear shall be less than 30%.
3. The guiding track is
smooth and free from
deformation.
4. No corrosion on the rod
surface and no deformation.
The bolts shall be free from
damage. The sealing quality
of the cylinder is good.
5. The indicating guiding rod
shall be smooth and the
indication is correct.
6. After the wheel being
reinstalled, it is still smooth.
7. After installation of the
gate, it is freely open or close
and the clearance between
the gate and the track shall
be smaller than 0.8mm.
8. The room and the panel
joint surface is smooth. When
the panel is closed, there
shall be no leakage.
2. Installation

1. Clean the slag gate with clean water and
check the surface or use clean water to clean
the gate base and anti-friction plate. If the
friction is too much, replace the plate.
2. Replace those deformed seriously.
3. Clean the gate frame and track with clean
water and check the smoothness of the track.
Replace if deformed and then install it on the

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frame and tighten with bolts.
4. Lift the gate to the frame and install it
based on the guiding track and put back the
positioning wedge.
5. Clean the threads of the piston rod with
diesel and check the threads. For minor
defects such as burr, use file to correct and
try with a nut. Replace with a new piston rod if
threads are damaged. The seal for the rod
shall also be replaced.
6. Lift the cylinder to the gate and get
connected. Caution: During the installation,
the piston rod shall be backed with the
exposed part and threads protected.
7. Reconnect the controlling piping and turn
on the gas/hydraulic controller to get the rod
and gate connected and fixed with nuts. Then
connect the gate with indication rod and
adjust the rod to a close position.
8. Open the gas/hydraulic controller so that
the gate opens fully and adjust the indication
rod correspondingly and adjust the indication
section so that it is correct.
9. Clean the guiding shaft and base with
diesel and replace O shaped ring and then
guide the eccentric part of the shaft to the
hole and tighten with bolt and put the sleeve
on and tighten with nuts. Note: Grease the
wheel and shaft before installation.
10. Turn the gas/hydraulic controller so that
the gate is located in an off position and use a
jack to jack the gate to the top of the frame.
Caution: Do not overuse force. Measure the
clearance between the slag gate and frame.
Before adjustment, the bolt shall be loosened
and rotate the shaft so that the guiding wheel
and the gate wedge is well contacted. Then
tighten the bolt and get the jack out. Measure
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again the gap and turn on the controller to
move the gate till it can move freely.
11. Use blade to clean the remnant on the
joint between the panel and slag room and
then close the panel.
11.2 Slag Crusher Maintenance and Service
Item Procedure and Cautions Quality Standard
1. Dismantling

1. Cut the motor power off.
2. Remove the bolts on the coupling hood and
remove the hood and the bolts on the couplings.
3. Remove the chain guard bolts and the guard
and remove the chain pin to get the chain off and
into the diesel.
4. Remove the shaft seal water pipe and water
outlet of the slag crusher.
5. Remove the connecting flange bolts between
the casing and the bottom of the slag hopper.
6. Heat the gears and chain wheels and remove
the gears and chain wheels with a puller.
Caution: before dismantling chain wheels, first
use steel wire to connect them to the moving
crane and tighten the wire a bit. When heating, it
shall be done evenly.
7. Remove the bearing seat at both sides of the
roller and use flame to heat the bearings internal
rings respectively and separate the bearing with
the roller.
Caution: Heating the rings evenly.
8. Remove the shaft seal filler cover bolts and
remove the cove and the filler.
9. Remove the bolts on the side plates of the
casing and remove the anti-friction ring and
separate the casing and side plates.
10. Lift the roller onto a wood and heat the sleeve

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and separate the sleeve from the roller with a
puller.
2. Service parts

1. Clean the chain wheel and gears in diesel and
check the gearing face. Use sand paper to grind
the shaft hole and chain grooves.
Caution: Grease the sand paper first before
application.
2. Use diesel to clean the bearing seat and
bearings. Check the joint of the seat and bearing.
Check the internal and external rings and rollers
of the bearings. Measure the bearing clearance.
If too large, replace bearings.
3. Clean the shaft sleeve and bearing jacket in
diesel and check the inside and outside. Use
sand paper to grind the sleeves and jacket.
Caution: Grease the sand paper first before
application.
4. Clean the casing and anti-friction ring with
clean water. Replace the ring if it is damaged.
5. Clean the roller teeth with clean water and
check the gearing face.
6. Clean the roller with diesel and check the shaft
surface. Replace if damage is there.
1. The chain wheel
and gear gearing face
shall be smooth, free
from corrosion,
breakage,
deformation. The
shaft chain groove
shall be free from
burr and deformation.
2. No corrosion in the
bearing seat and no
cracks. The bearing
roller shall be no
friction and the
bearing clearance
shall be 0.08-0.1lmm.
3. The wear of the
anti-friction ring shall
be less than 50%.
4. The wear of the
roller teeth shall be
less than 7 mm.
5. The roller shaft
shall be smooth and
free from corrosion
and the chain groove
shall be free from
burr and deformation.
6. There shall be no
corrosion or friction in
the sleeves.
3. Installation

1. Put the filler cover and water retaining ring
onto the roller shaft. The bearing to be heated in
oil and put on the shaft.
2. Use blade to clean the remnant on the joint
1. The joint face
between the casing
and slag hopper is
smooth with good
sealing quality. No
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face between casing and slag hopper and on the
side plates and then wipe clean with blade cloth.
3. Flush the casing inside with clean water and
install the anti-friction plate.
4. Install the side plate on one side of the casing.
Caution: Sealant shall be applied to the joint
surface and bolts.
5. Fix the bottom of the bearing seat and support.
6. Lift the roller and components to the casing
and install the other side plate.
7. Rotate the shaft so that the axial teeth of one
roller is located in the middle of that of another.
8. Heat the driving gear of the roller into the oil to
get heated and then put into the shaft and get to
the gearing location. The gear installation shall
be according to diagram 7-4.
Caution: When reinstalling the gears, the relative
position of the two shafts shall be temporarily
fixed.
9. Use a tommy bar to move the roller so that it is
in the middle of the casing.
10. Loosen the bolts between the bearing seat
and support, and add a gasket to the bearing seat
and support till the two shafts can rotate freely.
Then use filler gauge to measure the clearance
between the sleeve and casing shaft bore. If the
clearance is bigger than 0.05mm, then readjust
the gasket till it is smaller and ensure the shafts
can rotate freely.
11.Install the bearing seat position pin and
tighten the bottom position bolts of the bearing
seat and grease the bearing seat and install the
bearing seat cover.
Caution: Use blade cloth to clean the bearings
and the bearing seat before the cover is put on.
impurities in the
casing.
2. Good sealing
quality of the casing.
3. Installation tension
for the gear and chain
wheel is 0-O. 03mm.
4. Even clearance
between the roller
shaft and the side
plates. The roller
shaft could rotate
flexibly.
5. The shaft has good
shaft seal quality.

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12. Install the shaft seal filler, cover and water
retaining ring.
Caution: During the installation of the filler, the
filler direction shall be 90 degrees from each
other.
13. Use sand paper to grind the shaft gland
groove and key at the chain wheel side and then
heat the chain wheel shaft bore. Strike the chain
wheel with copper bar as cushion so that the
wheel goes to shaft and to the shaft shoulder.
Install the chain wheel position pin.
14. Move the slag crusher to under the slag
hopper and like the slag hopper and the crusher
with bolts, tightened.
Caution: The joint flange bolts between the
crusher and the slag hopper shall be applied
sealant.
4. Disintegrate the
reducer

1. Remove the bolts between the reducer and
coupling and bolts at the bottom of the reducer
2. Heat with a flame the wheel of the small chain
wheel and remove it from the reducer with a
puller.
Caution: Before removal, mark the position on
the shaft.
3. Turn on the oil drain of the reducer to get the
lubricant out and check the quality. If too bad,
replace the lubricant.
4. Open the side cover of the reducer and remove
the oil seal. Use copper tools to strike the gear
and bearing internal ring to get it separated from
the shaft.
5. Use diesel to clean the reducer box and
transmission gear and bearing and check the
shaft surface, gearing face and bearing.
6. Use diesel to clean the small chain wheel and
1. Lubricant no
quality change, no
emulsification.
2. Gearing face no
deformation, cracks,
wear, and corrosion.
3. Transmission shaft
surface smooth with
no wear.
4. Side cover of the
reducer no cracks
and box no cracks.

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the shaft bore.
5. Reducer
Installation
1. Use blade cloth to clean the reducer and clean
the joint surface of the casing.
2. Put the bearing and gear into the oil to get
heated and put onto the shaft.
3. When the transmission shaft components are
put into the reducer, fix them and rotate them to
check the flexibility.
4Install the side covers.
Caution: the joint surface shall be greased.
5. Fill in lubricant till the specified level.
6. Install the chain wheel to the marked position
and tighten it using bolts.
1. Inside the reducer
is clean and dry.
2. The tension of the
internal ring of the
bearing is
0.010.03mm and
for the gear is
0.030.05mm.

6. Assembling

1. Firmly fix the reducer to the foundation
platform and restore the chain. Adjust the bottom
position bolts to adjust the parralellity and
sagging amount.
2 Connect the reducer together with the
coupling and find the coupling center.
3Install the coupler and the chain guard.
4. Install the shaft seal water pipe and slag
crusher outlet.
1. The chain
parallelism deviation
shall be less than 2
mm. The free sagging
shall be smaller than
40mm.
2. The coupling
center deviation
smaller than 0.10mm.
3. No deformation
and leakage of the
chain guard.
4. The shaft seal
water pipe has no
leakage.
11.3 Slurry Pump Maintenance and Service
11.3.1 Technical Specifications
High pressure pumps are horizontal, single impeller, suction and centrifugal pump
with double casing. The casing has replaceable internal sleeves including impeller,
sleeve, plates, pump and cover. The pump is made of ductile cast iron. The front and the
back of the impellers have back blades to reduce leakage and to improve the life span
and efficiency. The inlet of the pump is horizontal and sealed with fillers and it is
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equipped with specialized shaft seal pump to provide enough water.
The bearing is single layer heavy duty cone bearing, capable of bearing maximum
axial and horizontal load. The bearing is oil lubricated and on both sides of the bearing
box, it all has sealing covers, labyrinth sleeves and rings to prevent any invasion of
foreign materials.
11.3.2 Slurry Pump Maintenance
Items Procedures and Cautions Quality Standard
1. Service
Preparation
1. Turn off the power for the slurry pump.
2. Close the inlet and outlet valves for the
slurry pump. Close the shaft seal water inlet
valve.
Caution: As the inlet and outlet valves are
closed, inside the pump and the inlet and
outlet piping there is still water and pressure;
therefore, the piping connections shall be
loosened to drain the remaining water and
pressure and then, dismantle the outlet pipe.
3. Remove the bolts for the coupling hood and
the hood and the bolts for the couplings.

2. Dismantling 1. Remove the connecting pin between the
pump and the motor.
2. Remove the inlet and outlet piping
connectors, and then remove the flange
bolts to get the piping out.
3. Remove the pump cover bolts with a
spanner and lift the cover to a designated
place. Caution: The cover shall be placed on
top of a wood or rubber.
4. Remove the 2 position iron plates for the
pump jacket and lift the jacket out.
5. Insert a steel pipe or bar into the impeller
chamber with another end on the ground.
Use special tube on the shaft gland and turn
anti-clockwise to get the impeller out of the
shaft.
Caution: Use steel wire to connect the

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impeller with the traveling crane, tightened.
a. Remove the filler cover bolts and the
cover and pull out all the fillers.
6. Strike the sleeve with hammer and copper
bar so that it gradually comes out. Remove
the 4 hold-down bolts between the bearing
components and the support, and the
adjustment bolts in the axial direction. Then
remove the bearing components and water
sealing ring.
7. Remove the locknut for the bearing
components with a hook wrench and the pins
at the front and back of the cover. Use an
iron bar to pry open the cover and pull the
labyrinth sleeve and cover out.
8. Use copper bar as a cushion to strike the
pump shaft so that it retreats till the bearing
comes out from the bearing box and then
remove the pump shaft from the bearing box.
9. Use heating methods evenly heat the
bearing and lubricant retainer ring on the
pump shaft to get them out of the shaft.
10. Get the positioning wedge for the front
plate of the pump cover out and place the
cover inlet side upwards on the ground. Use
copper bar as a cushion to separate the front
cover with the pump cover. Then remove the
nuts of the rear plate and strike the bolt ends
till the rear plate separate.
11. Mark the position of the filler box on the
pump and use copper bar as a cushion to
strike the filler box cover till it gets
separated with the pump.
3. Parts
Maintenance
and Service
1. Check the degree of wear on the pressure
enlarge outlet pipe of the slurry pipe. If
serious, replace.
2. Check the wedge shaped connecting
1. The pressure enlargement
outlet pipe wear shall be
smaller than 2mm. The
wedge seal ring shall be free
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rubber seal ring. If worn, replace.
3. Clean the front and back plates of the
pump cover and the cover with diesel and
check the level of wear of the back plate. If
serious, replace the back plate. If there is
crack on the pump cover, replace.
4. Clean the impeller jacket and check the
degree of wear. If the wear is serious at the
internal wall ant the outlet, replace it.
5. Clean the impeller and check the blades
and its working surface and if they are worn,
replace them.
6. Use diesel to clean the shaft sleeve and
water seal ring and check their surfaces.
7. Use diesel to clean the bearing and
labyrinth seal ring and check the bearings
rollers, internal and external rings and
labyrinth ring.
8. Clean the sealing filler box with diesel and
check the circumvent surface.
9. Clean the rear pump casing and check the
surface whether there are cracks. If there
are, replace.
10. Check the center straightness of the
support trough and check the trough surface
and support.
11. Clean the pump shaft with diesel and
check the bearings, oil retaining parts and
key way. Use fine greased sand paper to
grind the shaft and key way surface. Check
the threads of the shaft gland.
12. Periodically check oil level and quality of
the liquid coupler.
from worn and deformation.
2. The wear to the front and
back plates shall be less than
5mm. There shall be no
cracks on the pump cover.
The sealing gasket shall not
be worn.
3. No serious wear on the
internal wall and the outlet of
the jacket.
4. The wear to the impeller
front diameter and the front
and rear back blades shall
not be more than 3mm. The
blades shall be free from
corrosion and cracks. The
threads of the impeller shall
be damage free.
5. The sleeve surface shall
be smooth. Replace if the
wear is more than 1mm. The
clearance between the bore
of the sleeve and shaft shall
be 0.04mm-0.06mm. The
water seal ring shall be
complete. The surface shall
be not rusted or scaled.
6.The internal and external
ring of the bearing and rollers
shall be wear free, corrosion
free and no color change.
The tension is similar. The
clearance between the
internal ring and shaft shall
be -+0.01mm. The clearance
between the external ring
and bearing seat bore is
0.06mm-0.10mm, and the
same to the bearing box
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bore. No damage to the
labyrinth ring.
7. The filler box shall be free
from cracks with smooth
surface.
8. The bottom pump casing
9.The support trough center
straightness deviation shall
be less than 0.02 mm and the
trough surface shall be
smooth and wear free. The
support shall be wear free
and crack free.
10. The pump shaft surface
shall be smooth and free
from friction. The shaft
gland threads shall be free
from damage.
4. Assembling 1. Put the filler box into the pump to the
marked position and use copper bar as a
cushion to strike till the position is correct.
2. Put the back plate seal ring into the groove
and when it is smooth, then put the back plate
on to the pump with bolts.
Caution: Bolts shall be tightened with equal
strength.
3. Use blade cloth to clean the shaft surface
and then grease the surface.
4. Check and clean the joint surface and use
steel wire to lift the pump to connection place to
get connected with bolts.
Caution: Replace the sealing gasket for the
joint surface and the surface and the bolts shall
be sprayed with sealants.
5. Connect the pressure enlarging pipe with

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outlet pipe using connector.
Caution: Replace the rubber gasket.
6. Connect the inlet and water pipe with flange
and tightened with bolts equally.
Caution: The sealing gasket of the joint shall
be replaced.
11.4 Dehydration Granary Maintenance and Service
11.4.1 Brief introduction
The dehydration granary is a continuous dehydration equipment for the wet slag. A set of
the dehydration equipment consists of two granaries. When one of them is filled with slag,
dehydration process will initiate. The wet slag mixture will be switched to another granary. After
dehydration, the water content in the slag will be greatly reduced and the slag will be dry and
falling apart. Then through the slag gate to fill in a tipper to be transported. The two granaries
alternate to dehydrate.
The dehydration granary is shaped cylinder like on the top and cone like at the bottom. The
top has income slag gate and at the bottom, there is outgoing slag gate. The accessories
include: vibrators, water removal elements, diffusion grids, water flushing piping, and valves.
11.4.2 Procedure and Quality Standards
Item Maintenance Quality Standard
1.
Preparation
1. Check the equipment
maintenance and service logbook.
2. Prepare all the spare parts and
tools.
3. Process a maintenance and
service pass.
1. The slag incoming gate and water
flushing valve can be closed firmly
without leakage.
2. Turn off the power for the vibrators and
slag outgoing gate.
2.
Dehydration
granary and
accessories
Maintenance
1. Check whether there are cracks
or leakage from the dehydration
granary.
2. Check whether the columns and
support for the granary are firm.
3. Check the downflow weir is
leveled.
4. Check the diffusion grid and
1. The granary is firm and free from
cracks and leakage.
2. The columns and support are reliable.
3. If the distribution grooves are worn, it
shall be repaired by welding.
4. The downflow level (tooth bottom
level) difference shall be within 2mm.
5. The water removal elements shall be
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distribution grooves are worn.
5. Check whether the water removal
elements are scaled or clogged.
free from scales or clogging.
3. outgoing
slag gate
maintenance
1. The maintenance for the cylinder
shall be carried out according to the
appendix.
2. Examine and replace the
inflatable seal ring.
1) Remove the side plates at the
slag outgoing gate.
2) Open the slag outgoing gate
and remove the inflatable seal ring
positioning.
3) Remove the damaged
inflatable seal ring.
4) Clean the gate seat and inflate
the new inflatable ring together with
soap water sprayed and install it.
5) Install the positioning and bolts.
6) Install the slag outgoing gate
plates and close the gate.
3. Check the wearing level of the
gate.
4. Check the rollers, roller bearings
and lubrication.
5. The clearance examination and
adjustment for the gate and gate
seat
1) Use filler gauge to check the
clearance between the gate and the
gate seat. If the clearance is not
equal, then adjust..
2) The method: Adjust the
positioning bars at the gate corners
1. Cylinder sealing Ok without leakage.
2. The inflatable work pressure between
0.3~0.5MPa.
3. Replace damaged rings and worn
rings.
4. The rollers are complete and contacts
well with the track.
5. The roller bearing is Ok with enough
lubrication.
6. The clearance between the gate and
the seat is equal with a distance between
1.5 to 4mm.
7. The slag outgoing gate works well.
8. If the wall to the slag outgoing granary
is damaged, repair or replace it.
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to move it upwards or downwards
and measure the clearance with
filler gauge.
4. Flushing
water valve
overhaul
1. Check the valve property to
ensure it can be closed firmly.
2. Check the lead screw, valve seat,
valve and hand wheel to see
whether there is crack or damage
3. Check the support to the piping.
Weld any broken pipes.
4. Replace valve packing gland
1. The valve is free from leakage and
works well.
2. The piping is free from clogging and
with firm support.
3. Replace or repair damaged valves.
5. Trial Run
1. Try water experiment to the
dehydration granary to check the
gate property and sealing property.
2. Clear the work site.
1. The gates work well.
2. The inflatable sealing ring works well.
3. Ensure the site is clean with
equipments clearly labeled.
11.5 Maintenance of Concentration Tank and Buffer Tank
11.5.1 Maintenance Period: As per the system overhaul.
11.5.2 Maintenance Items
1. Check the slag removal of the concentration tank.
2. Check the slag removal of the buffer tank.
11.5.3 Maintenance procedure and quality standards.
Concentration tank clearance
1. Stop the slurry pump, and slag flushing pump. Close the slag incoming gate, water
removal gate and flushing gate of the dehydration granary.
2. First, use dredge to pump the slag water of the concentration tank to the ash slurry
pond, and then with mortar pump, pump to the disposal site.
3. When the slag water is lowered to a certain level, high pressure water flushing shall be
carried out to remove the slag at the bottom.
4. When it reaches the bottom, and the dredge pump refuses to work then a diving pump
shall be used.
5. Manually clears any clogs at the bottom until the bottom is clean.
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Buffer Tank Clearance
Ditto above.
11.6 Maintenance of Pumps in the Slurry System
11.6.1 High, Medium, and Low pressure pumps
High, medium, and low pressure pumps are horizontal, single impeller, suction and
centrifugal pump with double casing. The casing has replaceable internal sleeves
including impeller, sleeve, plates, pump and cover. The pump is made of ductile cast iron.
The front and the back of the impellers has back blades to reduce leakage and to improve
the life span and efficiency. The inlet of the pump is horizontal and sealed with fillers and
it is equipped with specialized shaft seal pump to provide enough water. The
maintenance to the three pumps is similar. The following takes slurry pump for example.
11.6.1.1 High Pressure Pump Maintenance
1. Service
Preparation
1. Turn off the power for the slurry pump.
2. Close the inlet and outlet valves for the
slurry pump. Close the shaft seal water inlet
valve.
Caution: As the inlet and outlet valves are
closed, inside the pump and the inlet and
outlet piping there is still water and pressure;
therefore, the piping connections shall be
loosened to drain the remaining water and
pressure and then, dismantle the outlet pipe.
3. Remove the bolts for the coupling hood and
the hood and the bolts for the couplings.

2. Dismantling 1. Remove the connecting pin between the
pump and the motor.
2. Remove the inlet and outlet piping
connectors, and then remove the flange bolts
to get the piping out.
3. Remove the pump cover bolts with a
spanner and lift the cover to a designated
place. Caution: The cover shall be placed on
top of a wood or rubber.
4. Remove the 2 position iron plates for the
pump jacket and lift the jacket out.

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5. Insert a steel pipe or bar into the impeller
chamber with another end on the ground. Use
special tube on the shaft gland and turn
anti-clockwise to get the impeller out of the
shaft.
Caution: Use steel wire to connect the
impeller with the traveling crane, tightened.
a. Remove the filler cover bolts and the cover
and pull out all the fillers.
6. Strike the sleeve with hammer and copper
bar so that it gradually comes out. Remove
the 4 hold-down bolts between the bearing
components and the support, and the
adjustment bolts in the axial direction. Then
remove the bearing components and water
sealing ring.
7. Remove the locknut for the bearing
components with a hook wrench and the pins
at the front and back of the cover. Use an iron
bar to pry open the cover and pull the labyrinth
sleeve and cover out.
8. Use copper bar as a cushion to strike the
pump shaft so that it retreats till the bearing
comes out from the bearing box and then
remove the pump shaft from the bearing box.
9. Use heating methods evenly heat the
bearing and lubricant retainer ring on the
pump shaft to get them out of the shaft.
10. Get the positioning wedge for the front
plate of the pump cover out and place the
cover inlet side upwards on the ground. Use
copper bar as a cushion to separate the front
cover with the pump cover. Then remove the
nuts of the rear plate and strike the bolt ends
till the rear plate separate.
11. Mark the position of the filler box on the
pump and use copper bar as a cushion to
strike the filler box cover till it gets separated
with the pump.
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3. Parts
Maintenance
and Service

1. Check the degree of wear on the pressure
enlarge outlet pipe of the slurry pipe. If
serious, replace.
2. Check the wedge shaped connecting
rubber seal ring. If worn, replace.
3. Clean the front and back plates of the pump
cover and the cover with diesel and check the
level of wear of the back plate. If serious,
replace the back plate. If there is crack on the
pump cover, replace.
4. Clean the impeller jacket and check the
degree of wear. If the wear is serious at the
internal wall ant the outlet, replace it.
5. Clean the impeller and check the blades
and its working surface and if they are worn,
replace them.
6. Use diesel to clean the shaft sleeve and
water seal ring and check their surfaces.
7. Use diesel to clean the bearing and
labyrinth seal ring and check the bearings
rollers, internal and external rings and
labyrinth ring.
8. Clean the sealing filler box with diesel and
check the circumvent surface.
9. Clean the rear pump casing and check the
surface whether there are cracks. If there are,
replace.
10. Check the center straightness of the
support trough and check the trough surface
and support.
11. Clean the pump shaft with diesel and
check the bearings, oil retaining parts and key
way. Use fine greased sand paper to grind the
shaft and key way surface. Check the threads
of the shaft gland.
12. Periodically check oil level and quality of
the liquid coupler.
1. The pressure enlargement
outlet pipe wear shall be
smaller than 2mm. The
wedge seal ring shall be free
from worn and deformation.
2. The wear to the front and
back plates shall be less than
5mm. There shall be no
cracks on the pump cover.
The sealing gasket shall not
be worn.
3. No serious wear on the
internal wall and the outlet of
the jacket.
4. The wear to the impeller
front diameter and the front
and rear back blades shall
not be more than 3mm. The
blades shall be free from
corrosion and cracks. The
threads of the impeller shall
be damage free.
5. The sleeve surface shall be
smooth. Replace if the wear
is more than 1mm. The
clearance between the bore
of the sleeve and shaft shall
be 0.04mm-0.06mm. The
water seal ring shall be
complete. The surface shall
be not rusted or scaled.
6.The internal and external
ring of the bearing and rollers
shall be wear free, corrosion
free and no color change.
The tension is similar. The
clearance between the
internal ring and shaft shall be
-+0.01mm. The clearance
between the external ring and
bearing seat bore is
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0.06mm-0.10mm, and the
same to the bearing box bore.
No damage to the labyrinth
ring.
7. The filler box shall be free
from cracks with smooth
surface.
8. The bottom pump casing
9.The support trough center
straightness deviation shall
be less than 0.02 mm and the
trough surface shall be
smooth and wear free. The
support shall be wear free
and crack free.
10. The pump shaft surface
shall be smooth and free from
friction. The shaft gland
threads shall be free from
damage.
4. Assembling 1. Put the filler box into the pump to the
marked position and use copper bar as a
cushion to strike till the position is correct.
2. Put the back plate seal ring into the groove
and when it is smooth, then put the back plate
on to the pump with bolts.
Caution: Bolts shall be tightened with equal
strength.
3. Use blade cloth to clean the shaft surface
and then grease the surface.
4. Check and clean the joint surface and use
steel wire to lift the pump to connection place
to get connected with bolts.
Caution: Replace the sealing gasket for the
joint surface and the surface and the bolts
shall be sprayed with sealants.
5. Connect the pressure enlarging pipe with

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outlet pipe using connector.
Caution: Replace the rubber gasket.
6. Connect the inlet and water pipe with flange
and tightened with bolts equally.
Caution: The sealing gasket of the joint shall
be replaced.

11.6.2 Backwashing Pump
Refer to the maintenance period, items and quality standards of the slurry pump.
11.6.3 Dredge Pump
11.6.4 Lift Pump

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