Manual for Erection Commissioning Operation & Maintenance of RAC

8/3/2019 Manual for Erection Commissioning Operation & Maintenance of RAC

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CHENGDU JUDING BOILER SUBSIDIARY EQUIPMENT

CO.,LTD

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


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Brief Description

1WWRCFBWWR

1WWR Seriesash cooler(RAC)(s) is a type of dry cooling and rotating equipment to be usedtechnically 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

Seriesash cooler(RAC)(s) has gained several national patents and the first prize at province-level in

new technolody and products .

2Type and InterpretingWWRXPQ

WWR rotary ash cooler

XP section type

Q rated ash flow rate


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Parts

Sr.No.

Description

Sr.No.

Description

1 Expansion joint 10 driving gear

2 Inlet ash box 11 reducer

3 Inlet ashsealer

12 motor

4 vent valve 13 seals for waterdivider

5 rolling ring 14 rotary joint

6 gear cover 15 spring supporting plate

7 outlet ash box 16 base

8 buffer wheel 17 supporting wheel

9 eye ring 18 driven gear


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Erection

Preparations for Erection

Check the components to be assembled as per the Equipment List and Confirm the machinesand 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 asper drawing, the size of the foundation blocks to be determined based on site soil and geologicalsurvey 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.


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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 inletash pipe about 50mm (under cold condition). An expansion margin for the furnace ash dischargingpipe along vertical direction required to be reserved. In the meantime the alignment of the outletash pipe and ash conveyer required to be well made, too.

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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 dischargingpipe. The bolts required to be fastened after sealing stuffing filled.

Attention: a further positioning and pre-tightening of the expansion joint bolts required to becarried out after the boiler expansion having got stabilized.


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Erection of Water Pipeline & Instrumentation

The c0oling water pipeline required to be mounted close to the equipment interface as perdrawing 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 contactpressure gauge, pressure transmitters and pressure switches, etc) and flow-meter on water outletpipeline.


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

Install temperature sensors on both ash inlet and outlet pipe. The sealing material required tobe perfectly installed to avoid ash giving off or leaking. Install the displacement sensors on bothsides of rolling ring and at the bottom of the same, in which the installation clearance required to beadjusted 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 ofwater outlet and to the rotating joint the near required to be water inlet pipe and the far to bewater outlet pipe .


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Schematic Plan for Pipeline Erection


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Electrical Connecting & Frequency Converter Setting 1

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

as per the drawings and instructions.

2

2. The electrical equipment (covering casing, box, motor and frequency converter, etc) required tbe 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 assleeve and the

cable laying required to be optimized.

4

4. After completion of the electrical connecting work , the data setting for frequency converterrequired to be

performed as per the Data Setting Schedule.


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Commissioning

After completion of the erection work, a critical work is to perform the commissioning ofRAC, 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 waterinto the cylinder slowly to vent the air until water squirting out; then close vent valve, full openwater inlet valve and water outlet valve, and check the water pipeline and cylinder to confirm

whether any water leakage observed or not.


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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 havingstopped 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 themotor is located on right (left) side, it is called Type Right (Type Left), the RAC will rotatecounterclockwise (clockwise), i.e. left rotating (right rotating).


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5.2

5.2. Slowly turn the master potentiometer mounted on the speed controller and measurewhether 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 waterpressure and the water flow when water inlet valve fully opened, and check whether the service ofthe 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.


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Operation

1

1. Start-up of RAC

Open water inlet valve (water inlet valve vent valve water outlet valve) start the subsequentequipment feed ash Start motor;

2

2. Shutdown of RAC

Stop ash feeding shut down RAC after emptying ash stop the subsequent equipment closewater inlet valve after temperature of RAC proper falling to the normal.

d dj d l


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3Speed Adjustment and Control 3.1

3.1 Electrical Control: Turn on power supply, switch on circuit breaker located inside the cabinetand power indicating lamp lights(green); Press Start button and Operation indicating lamplights; Start frequency converter to put motor and gear into service.

Shutdown of RAC: First stop frequency converter, and then press down Stop button after thefrequency 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 bothinlet & outlet water light, which will cut off the power supply of the frequency converter stoppingthe 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.


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


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3.5RS485420mAPLC

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 theequipment 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.


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When RAC is under on-load running , following the boiler load the discharging ash quantity iscontrolled 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


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3.7


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MAINTENANCE


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MAINTENANCE

Establishment of Repair & Maintenance Policy Required

1

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

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2. Every 8 hours the oil refilling with Intermediate-duty gear oil for supporting wheels, bufferwheels, gear rings and rolling rings and once six months the oil replacement for reducer arerecommended, 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 supportingwheels, buffer wheels and the hoop of the rolling ring in good conditions or not. The positions of thesupporting wheels required to be adjusted according to the actual wearing degrees in order tomaintain 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


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4

4. Under the condition of satisfactory ash discharging quantity, it is recommended to reducethe 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, seeUsage & 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 coolingwater 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

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


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9

9. The repair & maintenance work for electrical controls/ C&I equipment required to beexecuted by the professionals. The alarming indications from electrical controls/ C&I equipmentrequired 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 FrequencyConverter without special circumstance.

10

10. It is strongly recommended that the data of frequency converter is not allowed to bechanged 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 onlyafter 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 becalibrated or replaced in accordance with Safety & Technology Supervision Regulations for SteamGenerator.

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.


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Safety Protection Marks

Anti-Scalding

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

Troubleshooting


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Troubleshooting1

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 samefor Remote/ Local Start Switch, then the fitting face between rotating and static part and the gearengagement;

/

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

2


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2

2. Ash Leaking: Check the fitting seals and the sealing stuffing between rotating and static part andreplace the damaged seal with new one timely.

3

3. Water leaking: Stop ash draining immediately when water leaking from internal cylinder. Clearcompletely the ash inside RAC, stop water supply and RAC and carry out repair.


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

compensated.

Position Adjustment of supporting wheels


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Position Adjustment of supporting wheels1

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:

11. 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 bearinghousing required to be adopted

Adjustment buffer wheels of


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Adjustment buffer wheels of

The buffer wheels are used for fixing the axial displacement of RAC, which could be worn, loosened, damaged ormoved 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 Requirement1

1. A complete contact between the curved face of buffer wheel and the same of rolling ring required to beavailable.

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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


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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-tightenthe bolts.


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Manual for Erection Commissioning Operation & Maintenance of RAC

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