CHENGDU JUDING BOILER SUBSIDIARY EQUIPMENT CO.

,LTD

Manual for Erection, Commissioning, Operation & Maintenance of Rotary Ash Cooler

Brief Description
1WWRCFB WWR
1WWR Series ash cooler(RAC)(s) is a type of dry cooling and rotating equipment to be used technically for conveying and cooling of the hot bottom-ash from CFB/FBC boiler. Thanks to its technical performance and features of no ash leakage and no maintenance on the cylinder proper as well as long service life above 10 years , in particular the site practices in recent 10 years, WWR Series ash cooler(RAC)(s) has gained several national patents and the first prize at province-level in new technolody and products .

2 Type and Interpreting

WWRXPQ

WWR
XP Q

rotary ash cooler

section type rated ash flow rate

 Parts
Description Sr.No. Sr.N o. 10 Description

Expansion joint

driving gear

2
3

Inlet ash box

Inlet ash sealer

11
12

reducer
motor

4
5 6

vent valve
rolling ring gear cover

13
14 15

seals for water divider

rotary joint spring supporting plate

7
8

outlet ash box

16

base

17 buffer wheel supporting wheel

eye ring

18

driven gear

Erection
Preparations for Erection

Check the components to be assembled as per the Equipment List and Confirm the machines and tools for erection work. Foundation

Foundation Category: concrete; steel structure

C30 Concrete Foundation: C30 required to be adopted, the layout of foundation to be arranged as per drawing, the size of the foundation blocks to be determined based on site soil and geological survey and the embedded parts to be inserted according to the foundation construction drawing. Steel foundation: stress and load of the structures required to be confirmed.

Positioning of Equipment
1
50mm 1The position of RAC required to be fixed based on the alignment of the inlet expansion joint (inlet ash pipe) and the furnace ash discharging pipe, which required to be inserted into the inlet ash pipe about 50mm (under cold condition). An expansion margin for the furnace ash discharging pipe along vertical direction required to be reserved. In the meantime the alignment of the outlet ash pipe and ash conveyer required to be well made, too. 21/1000 2. The level and position of the equipment required to be assured, i.e. Level degree 1/1000

The base of RAC and supporting steel frame or the embedded steel plate of the concrete foundation allowed then to be well welded after satisfaction of the above-mentioned work 1 &2.
3

3. Then electric (or manual) ash valve allowed to be installed on the furnace ash discharging pipe. The bolts required to be fastened after sealing stuffing filled.
Attention: a further positioning and pre-tightening of the expansion joint bolts required to be carried out after the boiler expansion having got stabilized.

 Erection of Water Pipeline & Instrumentation

The c0oling water pipeline required to be mounted close to the equipment interface as per drawing and the further erection of the instruments as well as future daily maintenance to be also considered in the course of tubing . /

Install water inlet valve( correct direction emphasized), temperature sensors (single/dual hot resistance or bimetallic thermometer), water pressure gauge (electric contact pressure gauge, pressure transmitters and pressure switches, etc) and flow-meter on water inlet pipeline. /

Install water outlet valve( correct direction emphasized), safety valve, temperature sensors (single/dual hot resistance or bimetallic thermometer), water pressure gauge (electric contact pressure gauge, pressure transmitters and pressure switches, etc) and flow-meter on water outlet pipeline.

Note: The height of outlet water pipe required to be higher than that of RAC cylinder; the connection of the instrument required to be well sealed and the tightness required to be seriously checked after completion of the erection work.

Install temperature sensors on both ash inlet and outlet pipe. The sealing material required to be perfectly installed to avoid ash giving off or leaking. Install the displacement sensors on both sides of rolling ring and at the bottom of the same, in which the installation clearance required to be adjusted carefully in order to avoid vibration.

Ii is to be pointed out in particular that the height of water inlet pipe must be lower than that of water outlet and to the rotating joint the near required to be water inlet pipe and the far to be water outlet pipe .

Schematic Plan for Pipeline Erection

 Electrical Connecting & Frequency Converter Setting

1 1. The wiring for electrical control cabinet, motor , fan and site instrumentation required to be carried out

as per the drawings and instructions.

2. The electrical equipment (covering casing, box, motor and frequency converter, etc) required to be grounded

as per the specifications and the insulation and water-proof required to be checked, too.

3 3. The connecting required to adopt high temperature resistance cable with protection such as sleeve and the 4 4. After completion of the electrical connecting work , the data setting for frequency converter required to be

cable laying required to be optimized.

performed as per the Data Setting Schedule.

Commissioning

After completion of the erection work, a critical work is to perform the commissioning of RAC, which is very important to the normal operation and maintenance. 1 1. Before no-load running of RAC , rotate the cylinder until the vent valve upward;

2 2. In sequence, open vent valve water inlet valve water outlet valve, and supply water into the cylinder slowly to vent the air until water squirting out; then close vent valve, full open water inlet valve and water outlet valve, and check the water pipeline and cylinder to confirm whether any water leakage observed or not.

3/ 2. 3. Switch on Power Supply , start frequency converter and control RAC by means of Local /Remote running at low speed and then at high speed, which required to be running for about two hours respectively; 4 4. Stop of RAC . The power supply can be switch off only after the frequency converter having stopped completely. 5 5. Inspections during no-load running 5.1 5.1. Rotating direction of cylinder: Viewing from ash inlet side toward ash outlet side, if the motor is located on right (left) side, it is called Type Right (Type Left), the RAC will rotate counterclockwise (clockwise), i.e. left rotating (right rotating).

5.2

5.2. Slowly turn the master potentiometer mounted on the speed controller and measure whether the speed adjusting range meeting the technical requirement.

5.3 5.3. Check whether cooling water leakage at flange or rotating joint or not, measure the water pressure and the water flow when water inlet valve fully opened, and check whether the service of the instrumentation normal or not.

5.4 5.4. Check whether any abnormality or not , of vibration , noise, shock, gear engagement, dynamical and static fitting, temperature rise, motor current and voltage of the equipment. Any abnormal problem required to be solved immediately.

 Operation

1 1. Start-up of RAC

Open water inlet valve (water inlet valve vent valve water outlet valve) start the subsequent equipment feed ash Start motor; 2 2. Shutdown of RAC Stop ash feeding shut down RAC after emptying ash stop the subsequent equipment close water inlet valve after temperature of RAC proper falling to the normal.

3Speed Adjustment and Control

3.1

3.1 Electrical Control: Turn on power supply, switch on circuit breaker located inside the cabinet and power indicating lamp lights(green); Press Start button and Operation indicating lamp lights; Start frequency converter to put motor and gear into service. Shutdown of RAC: First stop frequency converter, and then press down Stop button after the frequency converter stops completely, and cut off power supply at last.

In case of high inlet & outlet water pressure, the high pressure alarm indicating lamps for both inlet & outlet water light, which will cut off the power supply of the frequency converter stopping the RAC;
In case of low water pressure, the low pressure alarm indicating lamp lights. The alarm can be relieved by pressing the button mounted on the control box.

3.2

3.2. The safety monitoring, control, adjusting, alarming , interlock and protection of start-up, shutdown, operation and accident of the RAC along with its assorted components will be controlled effectively with the detecting instruments and controlling equipment provided together with the RAC & its assorted components.

3.3

3.3. Pressure & Flow Protection:

The setting values for the water inlet/outlet electric-contact pressure gauges( i.e. pressure switch) or pressure transmitters and water flow-meters mounted on the inlet/outlet water pipelines required to be set at site according to the actual site conditions. In case the inlet/outlet pressure is beyond the set range, a pressure interlock signal will stop the RAC by sending out an acousto-optic alarm. The limited values for flow-meter to be set by observing directly the actual inlet water quantity, whose output could be selected in both switching and analog for alarm interlock and remote observation, i.e. an alarm will be given out when motor can not start or motor shuts down due to the mentioned setting value being beyond the set range and the reliability of the ash cooling and the safety of the equipment can be thereby ensured.

3.4 60 956095

3.4. Temperature Monitoring: The cooling water temperature is detected with temperature sensor( hot resistance) whose signal is sent to the temperature controller, in which after processing the signal will be indicated visually. The high limit of the water inlet/outlet temperature recommended to be set to 60 / 90 respectively (allowed to be adjusted based on the actual site conditions). In case the water inlet temperature is higher than 60 or the water outlet temperature higher than 90 ,an interlock signal given out by the temperature controller will stop the RAC and send out an acousto-optic alarm simultaneously.

Displacement Monitoring: The RAC is provided with displacement alarm device. It is stressed that a necessary check is required when a displacement alarm is sent out by the displacement alarm device. Based on the check result, a realignment of RAC and readjustment of the proximity switch required to be carried out until the alarm relieved.

3.5 RS485420mAPLC 3.5. Frequency Control: The speed of RAC is controlled by Frequency Converter aiming at governing motor speed stepless smoothly. The Frequency Converter is provided with communication interface of RS485 and standard analog signal of 420mA 420mA, which can be directly connected to PLC and IPC, and operated either at site or monitored and operated inside the Boiler Main Control Room. That is to say, as per the boiler bed pressure (or demand of the User) the bottom-ash quantity can be controlled by adjusting the speed of RAC.

3.6 3.6. For easy operating, the operating buttons and indicating lamps are provided and mounted on the front panel of the electrical control cabinet. A Stop button is designed for emergency stop under any circumstance, which can prevent the spreading of the accident. The indicating lamps can reflect the operating state of RAC. After confirmation of the water inlet pressure value within the set range and the equipment in good condition, RAC can be put into normal operation: Put the circuit breaker located inside the control cabinet on ON, both power indicating lamp and power supply indicating lamp for instruments light, showing RAC under standby status. Press down the button of Start on the front panel, rotating motor. The speed of motor is controlled and increased by frequency converter from Zero to the value demanded by the User, and the operating lamp lights in green. Simply press down Stop button mounted on the front plate to stop the motor in case of RAC being not demanded or any fault of RAC observed.


When RAC is under on-load running , following the boiler load the discharging ash quantity is controlled by adjusting RAC speed. The outlet ash temperature, water outlet temperature, operation water pressure, etc. required to be checked from time to time in order to ensure RAC running in good condition.

3.7

 MAINTENANCE

Establishment of Repair & Maintenance Policy Required

1. During operation of RAC, it is required to check regularly whether the vibration, noise and temperature rise as well as the current of the equipment normal or not; and to check whether the status of the ash conveying and cooling as well as the cooling water flow, water pressure and temperature in good conditions or not.

28 6 2. Every 8 hours the oil refilling with Intermediate-duty gear oil for supporting wheels, buffer wheels, gear rings and rolling rings and once six months the oil replacement for reducer are recommended, in which the oil quantity required to be within the oil scale range.

3
3. It is required to check regularly whether the contact and wearing status of the supporting wheels, buffer wheels and the hoop of the rolling ring in good conditions or not. The positions of the supporting wheels required to be adjusted according to the actual wearing degrees in order to maintain the centerline height and level of the cylinder as well as a uniform fitting clearance between dynamic & static parts on the inlet/outlet ash side

4 4. Under the condition of satisfactory ash discharging quantity, it is recommended to reduce the speed of RAC as much as possible in order to reduce the outlet ash temperature. 5 5. The acid cleaning cycle for RAC depends upon the cooling water quality. 6 6. The operating and maintenance for the electrical-controls and reducer. For details, see Usage & Maintenance Manual provided by the Manaufacturer 7 7. In case of long-term shutdown due to some reasons it is required to empty first the cooling water inside the cylinder and then to purge the same with compressed air (non-corrosive air) making the internals of cylinder dried to prevent from corrosion.

8. The rotary joint is a main wearing component, and once any water
leakage observed the sealing material required to be timely repaired or replaced.

9. The repair & maintenance work for electrical controls/ C&I equipment required to be executed by the professionals. The alarming indications from electrical controls/ C&I equipment required to be dealt with timely or to restart after having been checked & confirmed by the electricians. It is strongly suggested that the RAC can not be directly started by Frequency Converter without special circumstance.

10 10. It is strongly recommended that the data of frequency converter is not allowed to be changed by the operator at will. In case of the data change necessary done during repairing, the same required to be carried out by the concerned technician. The equipment can be restarted only after completion of the repair work and restoration of the original data completely. 11

11. The indication meters such as thermometers, pressure gauges and flow-meter are consumables, which are required to be daily patrol inspected by the site operators and to be calibrated or replaced in accordance with Safety & Technology Supervision Regulations for Steam Generator.
12

12. The safety valve has been set based on the site operation pressure in the workshop before delivery, which is required to be checked and set once a year.

 Safety Protection Marks

Anti-extrusion on gear wheel/supporting wheel/buffer whee

Anti-Scalding

Troubleshooting
1 1. RAC Unable to Start Check power system for control power and power supply
Clear the failure one by one based on the normal alarm signals 12

Check and Set : 1. Remote , 2. Local

/ Unable to start by Remote: Check first the setting value of frequency converter and the same for Remote/ Local Start Switch, then the fitting face between rotating and static part and the gear engagement; / Unable to start by Local: Check first the setting value of frequency converter and the same for Remote/ Local Start Switch and the cable connecting, then the fitting face between rotating and static part and the gear engagement;

2 2. Ash Leaking: Check the fitting seals and the sealing stuffing between rotating and static part and

replace the damaged seal with new one timely.

3

3. Water leaking: Stop ash draining immediately when water leaking from internal cylinder. Clear

completely the ash inside RAC, stop water supply and RAC and carry out repair.

() 4. Out-of-level of the cylinder/ heavy wear of supporting wheels The level of RAC cylinder will change after running a period of time , which can be observed by detecting the wear of supporting wheelsthe fitting clearance changes between rotating and static part and the gear engagement. In that case, a realignment for RAC cylinder required to be carried out.

For confirming the locations mentioned above, it is recommended to check the actual wear degree by hoisting the cylinder with a crane until achieving the position to be adjusted and compensated.

 Position Adjustment of supporting wheels

1 1. Loose the pre-tightening bolts of supporting wheels 2 2. Move supporting wheels inward and insert necessary gasket 3 3. Make the curved face of supporting wheel contact perfectly with the same of rolling ring 4 Pre-tighten the bolts. Attention:

1
1. The supporting wheels rotating flexibly indicates the adjustment of the bearing and supporting wheels satisfied. 2

2. A complete, flat shim with same thickness and a little bigger size then the housing base for bearing housing required to be adopted

Adjustment buffer wheels of

The buffer wheels are used for fixing the axial displacement of RAC, which could be worn, loosened, damaged or moved after long-term run and readjustment is therefore needful.

Adjustment Procedure:
1 1. Loosen completely the base blots 2

2. Adjust the positioning bolt until buffer wheel achieving its required position
Adjustment Requirement 1 1. A complete contact between the curved face of buffer wheel and the same of rolling ring required to be available. 23 2. The mounted clearance between buffer wheel and rolling ring required to be less than 3mm. 3 3. The base bolts and the support bolts required to be tightened tightly.

Adjustment of gear engagement

1 1. loosen completely the pre-tightening bolts of motor 2 2. Adjust the position of motor until satisfaction of the gear engagement and then pre-tighten the bolts.