Mm-m02~1

Project Dwg. No: P101-25-1701.03-W017

Forced Draft Fan MECHANICAL MAINTENANCE MANUAL PT PAITON ENERGY PAITON EXPANSION PROJECT

Forced Draft Fan Maintenance Manual No. MM-M02.01 Revision 003

Note • This mechanical maintenance manual is intended to provide the Paiton Expansion Project mechanical maintenance personnel with the basic understanding required to perform preventive, routine, corrective and overhaul maintenance activities on the subject equipment.

•

No part of this document may be reproduced for use by parties other than Mitsubishi Heavy Industries, Ltd. and Paiton Expansion Project.

Forced Draft Fans

Be sure to read this manual. Contents Safety

1

General

2

Specifications

3

Preventive Maintenance

4

Disassembly and Reassembly

5

Corrective Maintenance

6

Recommended Lubrication

7

Appendixes

Contents

Contents Revision Record································································································· i Important Information·························································································ii Warranty ··········································································································· v Limitation of Liability·························································································vii Copyright········································································································· viii Personnel to whom the Manual is Directed ······················································ix Contact Address································································································ x Abbreviations ····································································································xi List of Vendor Manuals ···················································································xiv Arrangement of the System Maintenance Manual···········································xv

Chapter1

Safety ____________________________

1.1

Feature of Forced Draft Fan Safety ················································· 1-1

1.2

Warnings Description ······································································· 1-2 1.2.1

Definitions of “Serious Injury”, “Minor Injury”, “Serious Damage to Property”, and “Minor Damage to Property” ······ 1-3

1.2.2

Symbol ················································································· 1-4

1.2.3

Hazard Warning Label ························································· 1-5

1.2.4

Hazard Area ········································································· 1-7

1.3

Risk Assessment Standard ······························································ 1-8

1.4

Safety Measures ············································································ 1-10 1.4.1

Work Permit System (Lockout/Tagout) ······························ 1-10

1.4.2

General Cautions on Personnel in Working Area··············· 1-11

1.4.2.1 Cautions against Rotating Equipment································ 1-11 1.4.2.2 Cautions against High Voltage Section ······························ 1-11 1.4.2.3 Cautions against High Temperature Sections ···················· 1-12 1.4.2.4 Cautions for Steam Leak in the Plant································· 1-13 1.4.2.5 Cautions against Oil/Coal Leak in the Plant······················· 1-13 1.4.2.6 Cautions against Chemicals ·············································· 1-14 1.4.2.7 Cautions against Combustible Materials/Storage Areas ···· 1-14 1.4.2.8 Cautions against Lack of Oxygen ······································ 1-15 Rev.003

1.4.2.10Cautions against Sharp Objects········································ 1-16

MM-M02.01

1.4.2.9 Cautions against Lifting Heavy Object ······························· 1-16

1.4.2.12Cautions using Crane ······················································· 1-17

1.4.2.11Cautions using Fork Lift····················································· 1-16 1.4.2.13Disposal ············································································ 1-18 Forced Draft Fan Mitsubishi

1

Contents

Chapter1 1.5

Safety (Continued from previous page…) Emergency Measure······································································ 1-19 1.5.1

Evacuation in an Emergency ············································· 1-19

1.5.1.1 Evacuation Route······························································· 1-19 1.5.1.2 Evacuation of Disabled persons who cannot move by themselves ···································································· 1-19 1.5.1.3 Evacuation from Power House ·········································· 1-20

Rev.003

Fire Accident ······································································ 1-21

1.5.3

Earthquake········································································· 1-22

1.5.4

Explosion Accident····························································· 1-22

1.6

Qualification and Training ······························································ 1-23

Chapter2

General ___________________________

2.1

Purpose···························································································· 2-1

2.2

References······················································································· 2-1

2.3

Overview of the FDF ········································································ 2-2

2.4

Components····················································································· 2-7 2.4.1

Casing·················································································· 2-7

2.4.2

Rotor ···················································································· 2-9

2.4.3

Moving Blade Regulating Mechanism································ 2-10

2.4.4

Main Bearing Assembly ····················································· 2-11

2.4.5

Control/Lubricating Oil System ·········································· 2-11

2.4.6

Coupling············································································· 2-12

Chapter3

Specifications _____________________

Chapter4

Preventive Maintenance _____________

4.1

Prerequisites ···················································································· 4-1

4.2

MM-M02.01

1.5.2

4.3

Forced Draft Fan Mitsubishi

4.1.1

Scheduling ··········································································· 4-1

4.1.2

Departmental Interface/Notification······································ 4-2

4.1.3

Isolation of Equipment ························································· 4-2

4.1.4

Safety Precautions······························································· 4-2

Routine Maintenance ······································································· 4-3 4.2.1

Preparation ·········································································· 4-3

4.2.2

Inspection and Maintenance ················································ 4-4

Annual Outage Maintenance ························································· 4-10 4.3.1

Preparation ········································································ 4-10

4.3.2

Inspection and Maintenance ·············································· 4-11

2

Contents

Disassembly and Reassembly ________

5.1

FDF Disassembly and Reassembly ················································· 5-1

5.2

Rotor Disassembly and Reassembly ············································· 5-18

5.3

Bearing Disassembly and Reassembly ········································· 5-27

5.4

Moving Blade Regulating Mechanism Linkage Disassembly and Reassembly ······················································· 5-33

5.5

Coupling Disassembly and Reassembly········································ 5-38

Chapter6

Corrective Maintenance _____________

6.1

Prerequisites ···················································································· 6-1

6.2

Preparation ······················································································ 6-2

6.3

Troubleshooting ··············································································· 6-2

Chapter7

Recommended Lubrication __________

MM-M02.01

Rev.003

Chapter5

Forced Draft Fan Mitsubishi

3

Contents

Appendixes Appendix A

Torque Chart ······································································A-1

Appendix B

Spare Parts ········································································B-1

Appendix C

Special Tools ····································································· C-1

Appendix D

Coupling Alignment ··························································· D-1

Appendix E

Applicable Vendor Drawings ··············································E-1

Appendix F

MV Packing Insertion ·························································F-1

Appendix G

Applicable Vendor Manuals··············································· G-1

Appendix H

Part List ············································································· H-1

Appendix I

Moving Blade Paint Data Sheet ·········································· I-1

MM-M02.01

Rev.003

List of Figures Figure1-1

Types of Hazard Warning Label ········································· 1-6

Figure 1-2

FDF Mapping for Hazard Areas ········································· 1-9

Figure 2-1

Air & Flue Gas P & I D ······················································· 2-3

Figure 2-2

FD Fan Outline ································································· 2-4

Figure 2-3

FD Fan Sectional View······················································· 2-5

Figure 2-4

FD Fan Cutaway View ······················································· 2-6

Figure 2-5

FDF Casing Assembly······················································ 2-13

Figure 2-6

Rotor Assembly ································································ 2-14

Figure 2-7

Moving Blade Regulating Mechanism Assembly ············· 2-15

Figure 2-8-1

Linkage Mechanism Assembly········································· 2-16

Figure 2-8-2

Blade Sticking Detector ···················································· 2-17

Figure 2-9

Bearing Box Assembly ····················································· 2-18

Figure 2-10

FDF Lube and Control Oil P & I D···································· 2-19

Figure 2-11

Intermediate Shaft and Coupling Assembly ····················· 2-20

Figure 3-1

Performance Curve ···························································· 3-4

Figure 4-1

FDF Clearance Details····················································· 4-18

Figure 5-1A

Overhaul Plan for FDF – 1/2 ············································ 5-15

Figure 5-1B

Overhaul Plan for FDF – 2/2 ············································ 5-16

Figure 5-2

Supporting Procedure for FDF Rotor ······························· 5-17

Figure 5-3

MB Hydraulic Mechanism – Exploded View····················· 5-24

Forced Draft Fan Mitsubishi

4

Contents

List of Figures MB Mechanism Exploded View········································ 5-25

Figure 5-5

Supporting Procedure for Rotor Disassembly & Reassembly ·································································· 5-26

Figure 5-6

Bearing Box – Exploded View·········································· 5-31

Figure 5-7

Supporting Procedure for Bearing Removal ···················· 5-32

Figure 5-8

MB Regulating Linkage Mechanism – Exploded View····· 5-37

Figure 5-9

Centering Tool Assembly for Intermediate Shaft ·············· 5-41

Figure E-1

Forced Draft Fan Outline Drawing ·····································E-2

Figure E-2

Forced Draft Fan Sectional Drawing ··································E-3

Figure E-3

FDF Lubricant & Control Oil Unit P & ID ····························E-4

Figure E-4

FDF-A Lubricant & Control Oil System Unit Assembly – 1/2···································································E-5

Figure E-5

FDF-A Lubricant & Control Oil Unit Assembly – 2/2···································································E-6

Figure E-6

FDF-B Lubricant & Control Oil Unit Assembly – 1/2···································································E-7

Figure E-7

FDF-B Lubricant & Control Oil Unit Assembly – 2/2···································································E-8

Figure F-1

MV Packing Insertion ·························································F-2

Figure F-2

MV Packing Material & Dimension·····································F-3

MM-M02.01

Rev.003

Figure 5-4

Forced Draft Fan Mitsubishi

5

Contents

List of Tables Risk Assessment Standard ················································ 1-8

Table 3-1

Forced Draft Fan ································································ 3-1

Table 3-2

Forced Draft Fan-Motor······················································ 3-2

Table 3-3

FDF Control Oil Unit··························································· 3-3

Table 4-1

Routine Maintenance Checklist·········································· 4-7

Table 4-2

Annual Outage Maintenance Checklist ···························· 4-14

Table 6-1

Troubleshooting – Forced Draft Fan ·································· 6-3

Table 7-1

FD Fan Recommended Lubrication ································· 7-1

Table A-1

Torque Chart ······································································A-1

Table B-1

Recommended List of Strategic Spare Parts (Off-Shore) ·········································································B-2

Table C-1

FD Fan Special Tools ························································ C-2

Table H-1

Part List (1 of 8)································································· H-2

Table H-2

Part List (2 of 8)································································· H-5

Table H-3

Part List (3 of 8)································································· H-8

Table H-4

Part List (4 of 8)································································H-11

Table H-5

Part List (5 of 8)······························································· H-15

Table H-6

Part List (6 of 8)······························································· H-18

Table H-7

Part List (7 of 8)······························································· H-21

Table H-8

Part List (8 of 8)······························································· H-24

Table I-1

Moving Blade Paint Data Sheet (1 of 2)······························ I-2

Table I-2

Moving Blade Paint Data Sheet (2 of 2)······························ I-3

MM-M02.01

Rev.003

Table 1-1

Forced Draft Fan Mitsubishi

6

Revision Record Revision Issue Date

Date Revised

Pages Inserted

2-11, 2-13, 2-18

Revised in accordance with design progress.

26. May. 2011

26. May. 2011

-

2-14 ~ 2-16

Revised in accordance with Drawing review sheet

26. May. 2011

26. May. 2011

-

2-17

Added drawing of blade sticking detector in accordance with drawing review sheet (PE-MHIN-PEHO-T-11025)

26. May. 2011

26. May. 2011

-

3-4

Added performance curve in accordance with drawing review sheet (PE-MHIN-PEHO-T-11025)

26. May. 2011

26. May. 2011

-

4-18, 4-14~4-18

Revised in accordance with design progress.

26. May. 2011

26. May. 2011

-

5-28

Corrected an error.

26. May. 2011

26. May. 2011

-

Appendix B

Revised updated status

26. May. 2011

26. May. 2011

-

F-3

Revised in accordance with drawing review sheet (PE-MHIN-PEHO-T-11025)

26. May. 2011

26. May. 2011

-

Appendix-H

Added the part list.

26. May. 2011

26. May. 2011

-

4-14 G-19~G-21 G-28, G-29

Added the comments in accordance with drawing review sheet (PE-MHIN-PEHO-T-13681)

27.Feb. 2012

27.Feb. 2012

3-1, 4-5, 4-14, 4-18, 6-3

Added the comments in accordance with design progress.

27.Feb. 2012

27.Feb. 2012

E-4

Revised the updated status.

27.Feb. 2012

27.Feb. 2012

2-5 Appendix I

Added the comments in accordance with drawing review sheet (PE-MHIN-PEHO-T-13681)

27.Feb. 2012

27.Feb. 2012

4-8, G-16

Revised in accordance with design progress.

27.Feb. 2012

27.Feb. 2012

G-120~G-128

Added Line Filter manual in accordance with design progress.

27.Feb. 2012

27.Feb. 2012

Rev.003

Description of Revision

5-9, 5-13

Added the comments in accordance with NCR (MBK-N-NCR-0047).

23. March.2012

23. March.2012

MM-M02.01

Page Number

E-4

Revised updated status.

23. March.2012

23. March.2012

Forced Draft Fan Mitsubishi

i

Important Information Purpose of the Plant Usage This plant is designed to generate electric power of 815 MW by the steam turbine generator. The plant is used for the electric power generation purpose that supports stable and reliable electric power supply to the power grid and supplying steam for auxiliary equipment in the power station.

General 1.

To satisfy the purpose mentioned above, the following points must be strictly observed. a)

The operation, maintenance and inspection of the Forced Draft Fan must be performed by the persons who have basic technical knowledge and have been trained concerning the hazard of the Forced Draft Fan and the avoidance of the hazard.

b)

The operators and maintainers must read and understand these manuals before starting the operation, maintenance or inspection. It is often experienced that serious damages to the equipment or personnel have occurred by the unexpected action of operators or maintainers who do not understand well about the equipment.

c)

The modification or change of operational specification must be performed under MHI supervision or as per the written acceptances of MHI. The modification or change of specification causes not only a decline in performance but also a decline in safety for operation of the equipment. The customer is requested to discuss with MHI about any planned modification or changes before the work actually starts.

MM-M02.01

Rev.003

The address for MHI to be contacted is shown in this chapter. 2.

The operation and maintenance must be performed according to the applicable laws and regulations at the location of the power station.

3.

Disposal from the power station must be treated to satisfy the local regulations.

4.

The copyright of software, drawings and other documents provided by MHI at all times, is still reserved by MHI.

Forced Draft Fan Mitsubishi

ii

5.

Use or copying of the whole or part of any information provided by MHI for any purpose other than operation and maintenance of this plant without written consent is strictly prohibited.

Important General Notice for Safety 1.

The operator and maintainer must have knowledge about the equipment to maintain good operating condition and to avoid danger when using the equipment and systems.

2.

The protection measures must satisfy all of the operational functions.

3.

The safety activity must be planned systematically as a “Safety and Health management system” and operate continuously. The Safety and Health management system must include the following points, a) Instruction for the use and the maintenance of the personal protective equipment issued to operators and maintainers b) The establishment of a work management organization to make clear the operation directives and work procedures c) Implementation of training for operator and maintainer

4.

The customer must train the operators and maintainers to act actively and to prevent the occurrence of an accident by using their knowledge of the power plant.

5.

The customer must make the operators and maintainers understand that the most important purpose of safety control is to protect all personnel from accidents and also to maintain operation of the plant without troubles.

6.

To prevent accidents involving personnel and equipment, it is necessary to observe the notices of this manual and to keep the correct operation according to the description provided in this manual. If the notices are not observed, the following dangers could occur to the operators or to the maintainers.

Rev.003

7.

a)

Risk of a fatal accident

b)

Danger to lose his health and fitness

c)

Danger of damage to the equipment

MHI can not forecast all possible dangers existing in the plant such as danger due to human error and/or dangers caused by the operating environment.

MM-M02.01

As this manual and the alert label cannot cover all of the dangers, the operators and maintainers have to pay their full attention to all general safety notices.

Forced Draft Fan Mitsubishi

iii

8.

MHI can not be responsible for damages and injury caused by neglecting the notices in this manual, and other necessary general notices.

Instruction of this Manual This manual is provided for people familiar with the use of English. If some person not familiar with English is going to operate the plant, the Customer must train him specially.

2.

The warning labels are to be expressed in the English language.

3.

This manual contains optional matters.

4.

Some figures in this manual include internal parts of the equipment which may not be obvious, when looking at the completed equipment drawing.

5.

MHI may change the content of this manual without notice.

6.

This manual is intended for the use by the operators and maintainers and it must be accessible to them at all times.

7.

If the Customer needs more detailed information, please contact MHI local office or MHI’s official agent.

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1.

Forced Draft Fan Mitsubishi

iv

Warranty •

The provisions set forth in this section are in addition to all liability and warranty disclaimers and limitations set forth in the Contract, whether arising under law or from course of performance, course of dealing, or usage of trade.

•

Nothing in these provisions shall constitute or be deemed to constitute any additional liability undertaking or warranty, express or implied, with respect to the Plant. All capitalized terms used, but not defined in this Warranty Limitations section shall have the respective meanings ascribed to them in the Contract.

•

The Contract Warranties are subject to the construction, installation and Commissioning works having been performed in full compliance with the requirements stated in (a) the Contract, (b) all manuals provided by MHI, including this manual, (c) all applicable rules, regulations and laws prevailing in the location where the Plant has been installed and will operate, and (d) any other instructions, if any, provided by MHI (collectively, “Rules and Requirements”). The Contract Warranties will NOT cover any accidents, partial or total failure of the Plant, losses or damages to personnel or property (including, without limitation, the Plant’s components, parts, systems and other equipment), or any other liability (collectively, “Accidents and Damages”) in the case of any breach of the stated Rules and Requirements.

•

For the detailed terms and conditions of the warranty concerning the Works and Project, refer to the Contract.

In addition to the foregoing, the Contract Warranties will NOT cover any of the following Accidents and Damages: Accidents and Damages caused by any deviation from the Rules and Requirements;

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•

Forced Draft Fan Mitsubishi

v

Accidents and Damages caused by the modification or re-installation of the Plant after the original installation, or caused by operation of the Plant for a purpose other than that for which it is designed;

•

Accidents and Damages caused by natural disasters or accidents during transfer or related handling;

•

Accidents and Damages occurring after the term of the warranty has expired;

•

Accidents and Damages due to faulty operation or operation not in accordance with the Rules and Requirements;

•

Accidents and Damages due to inappropriate maintenance or servicing performed by the Customer, its personnel or any other party.

•

Accidents and Damages caused by any components, parts, systems or other equipment other than those delivered by MHI;

•

Accidents and Damages caused by unidentifiable reasons including loss of the damaged parts which is necessary to pinpoint a cause of the failure;

•

Accidents and Damages caused by referring to inadequate, or incorrect references, data or information provided by the Customer;

•

Accidents and Damages or rust/corrosion due to inadequate handling and/or storage by the Customer; or

•

Accidents and Damages due to handling, storage and/ or use of the Plant under severe conditions or in an environment that does not meet the design specification conditions.

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Limitation of Liability Use and Disposal •

Nothing in this Limitation of Liability section or manual shall constitute or be deemed to constitute any additional liability undertaking or warranty, express or implied, with respect to the Plant. All capitalized terms used, but not defined in this Limitation of Liability section shall have the respective meanings ascribed to them in the Contract.

•

The contents of this manual are subject to change without prior notice and without any obligation or liability to MHI.

For Documents and Safety Training •

Use of the Plant must be limited to the use specified by MHI, including without limitation, use of the Plant in accordance with the Contract, this manual, all Safety Manuals, all applicable laws and regulations, and any other instructions, if any, provided by MHI. The Plant components, parts, systems and other equipment (collectively, “Equipment”) must be appropriately disposed of in accordance with the Contract, this manual, all Safety Manuals, all applicable laws and regulations, and any other instructions, if any, provided by MHI.

For Damage to the Plant

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•

The Customer’s personnel must read, understand and abide by all documents provided by MHI, including without limitation, the operation and maintenance manuals, safety manuals, and instruction manuals (collectively, “Safety Manuals”) and must have received all required and/or necessary safety training prior to the start of their work. Persons who have not received such safety training are not permitted to work on the installed Plant. This initial training, however, is merely the minimum requirements prior to allowing any personnel to work on the installed Plant. The Customer must, on a continual and regular schedule, give up-to-date training to its personnel on safety requirements, provide testing or other methods to confirm their understanding of the safety training, and confirm that they have the physical and mental capability to perform their respective roles. The Customer’s obligation for safety training and personnel supervision is an ongoing obligation and must be continuously performed and kept current throughout the operation of the Plant. Accidents, partial or total failure of the Plant, damage to personnel or property, loss, injuries, and other liability (collectively, “Liability”) caused by inadequate safety training or the Customer’s personnel’s failure to abide by the documents provided by MHI are expressly excluded from the coverage of any warranty provided by MHI and are the sole and exclusive responsibility of the Customer.

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•

MHI will NOT be liable for any Liability caused by modification or changes made in Plant-related documents (including any Safety Manual) by anyone other than MHI.

For Damage to the Plant Accidents may occur by use of Equipment that is acquired from anyone other than MHI or anyone not appointed by MHI to modify or repair this Plant. The Customer shall not be permitted to modify or repair the Plant or change Equipment of the Plant without MHI’s prior written approval, under any circumstance.

•

MHI will NOT be liable for any Liability resulting from any abuse, misuse, misapplication of the Equipment supplied by MHI.

•

MHI will NOT be liable for any Liability caused by an act by the Customer in violation of the Contract, this manual, any applicable law or regulation, or any Safety Manual or any other instruction provided by MHI, including without limitation, a change of the installation environment or the removal and installation of any Equipment in a location different to that originally selected by MHI.

•

MHI will NOT be liable for any Liability caused by a defect, imperfection, or fault, in material or Equipment that was used during a repair, even when such a repair was performed by or under an instruction given by MHI.

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viii

Copyright COPYRIGHT © 2009, MITSUBISHI HEAVY INDUSTRIES, LTD. ALL RIGHTS RESERVED. ANY REPRODUCTION IS EXPRESSLY PROHIBITED. All of the content contained in this manual is protected by Japanese, International and/or United States copyright laws.

•

All copyright, trade secrets, and other proprietary and intellectual property rights in the documents provided by Mitsubishi Heavy Industries, Ltd. (“MHI”) (including safety-and-instruction manuals) are at all times owned and reserved by MHI. Subject to your compliance with the restrictions set forth below, MHI grants to you a limited, non-exclusive license in the copyright for the sole purpose of allowing you to use, operate, maintain and inspect the Plant.

•

Use, copying, other reproduction of the whole or part of the documents provided by MHI (including safety-and-instruction manuals) for any purpose other than the purpose described above without MHI’s prior written consent is strictly prohibited.

•

The act of rewriting, translating, modifying, revising, creating electronic copies, uploading, selling, sublicensing, or otherwise disclosing the whole or part of the manuals is strictly prohibited.

•

Except as specifically set forth above, no right, title or license to the documents provided by MHI, whether arising from contract, implication, and estoppel or otherwise, is being granted or otherwise transferred.

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•

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ix

Personnel to whom the Manual is directed This Manual was prepared for all personnel who will participate in the operation and maintenance of the plant, and other related mechanical plant and equipment installed. In this Manual, MHI classifies personnel into the following two classes based on their ability, experience and their attitude to the safety of personnel, and the plant installed. Only the personnel recognized by the Customer as trained personnel are allowed to perform the operation and maintenance specified in the manuals. Maintainers and Operators are required to have read and understood the contents of the safety, operation, and maintenance manuals and sufficiently understand the work procedures before actually starting their tasks.

Operator

Operators following the instructions of their supervisor or the Shift Charge Engineer are permitted to handle materials to be used in the operation of the plant. Operators are allowed to turn on the power supply, startup equipment, open up or remove covers or panels on receipt of an instruction or authorization from their superior. Operators are permitted access to emergency stop devices following instructions given by their superior when dangerous or hazardous situations are recognized.

Maintainer

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Maintainers are permitted to perform maintenance on the plant. They will also perform troubleshooting routine and periodical inspections of the installed equipment. The maintainer will also work under the supervision of MHI’s supervisors during on-the-job training and annual maintenance and overhaul work if MHI’s supervisors are requested to witness periodical inspections, etc. Maintainers MUST have attended the training programme initially provided by MHI and subsequently by the Customer, and they must have obtained the necessary knowledge and maintenance skills to understand the characteristics of their tasks before actually starting their work.

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Contact Address For any question or any clarification required, please do not hesitate to contact MHI through the following address (es).

For Support before Operation: MITSUBISHI HEAVY INDUSTRIES, Ltd. Nagasaki Shipyard & Machinery Works

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1-1, Akunoura Machi, Nagasaki 850-063

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Abbreviations Abb.

Expanded Form

Abb.

Expanded Form

American Society for Testing and Materials

FDF

Forced Draft Fan

BMCR

Boiler Maximum Continuous Rating

MB

Moving Blade

CCW

Counter-Clock Wise

NDE

Non-Drive End

CCCW

Closed Circuit Cooling Water

NOL

Normal Oil Level

DE

Drive End

PPE

Personal Protective Equipment

DP

Differential Pressure

DTI

Dial Test Indicator

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ASTM

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xii

List of Vendor Manuals Description

Manufacturer

1

Handling Manual of Lubrication Oil Unit for FD Fan

Daikin Hydraulic Engineering Co. Ltd. Japan

2

Handling Manual of Pleated Type Accumulator

Nippon Accumulator Co., Ltd. Japan

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Item No.

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Arrangement of the System Maintenance Manual This manual is arranged as follows.

Chapter 1 Explains health and safety issues during installation, operation, maintenance, disassembly and reassembly of the FDF.

Chapter 2 Describes the construction, purpose, and function of the FDF and the associated parts.

Chapter 3 Describes the FDF parts, using the relevant Data Sheets.

Chapter 4 Describes the Preventive, Routine, and Outage Maintenance.

Chapter 5 Describes the disassembly and reassembly procedures, necessary to obtain access to internal parts for inspection and repair during FDF overhaul.

Chapter 6 Describes the corrective maintenance procedures to be followed to investigate, identify and remedy defects occurring during operation.

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Describes the lubricants and its frequency and quantity of applications.

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Chapter 7

Includes Torque Chart, Spare Parts, Special Tools and Vendor Drawings/ Documents

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Chapter 1

Safety

C h a p t er

1 S af et y 1.1

Feature of Forced Draft Fan Safety The function of the Forced Draft Fan is to supply combustion air to the steam generator. Hence this is very critical equipment for uninterrupted power generation. The FDF is an axial fan with a rotor (moving) blade pitch control mechanism for controlling the air flow and is fitted with aluminum blades. Absolute care must be taken during maintenance of these fans and also cleanliness of the fan internal is very important. If not, the fan blades will be damaged by the foreign particles and will lead to the reduction of boiler load or stoppage of generation due to non availability of the fan. Like any other critical rotating equipment, this fan also has many clearances with close tolerance. Utmost care is to be taken to maintain these values as per this manual. Incorrect clearances can either lead to the damage of the fan or hamper the performance of the equipment. For the proper functioning of the bearings and also for the control of the blade pitch, the FDF is provided with an oil system. Any oil leak and foreign particles in the system is not only dangerous to the equipment but it also can cause the area around the fan to be slippery leading to the fall of operating personnel. Oil leakage and foreign particles also can lead to a fire. Considering the above fact, a constant monitoring of the fan and its oil unit is necessary. During normal conditions, all the standard safety precautions are to be followed.

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During outage maintenance, proper safety procedures are to be followed by the operating personnel who will purge all systems before issuing a Permit to Work to the Maintenance Staff.

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1-1

Chapter 1

1.2

Safety

Warnings Description Safety of personnel working in the power plant is the most important matter. And all kinds of consideration to avoid dangerous conditions are studied and applied to the design of the power plant. However, certain risks are unavoidable due to the nature of the plant. This manual classifies the severity and hazard level of such risks by two categories, “DANGER” and “CAUTION”. Read and understand the indications thoroughly before operation or maintenance of the plant. The contents of wordings, “DANGER” and “CAUTION” are described as follows; Kinds

Meaning of Warnings “DANGER” indicates an imminently hazardous situation during use of the Forced Draft Fan, which, if not avoided, could result in death or serious injury, or serious damage to the property or environment. “CAUTION” indicates a potentially hazardous situation

CAUTION

during use of the Forced Draft Fan, which, if not avoided, may result in minor injury or minor damage to the property or environment.

This manual also uses the following indicators in addition to the hazard level indications described so far.

Kinds

Meaning of Warnings “IMPORTANT” describes the particular information or items that personnel must know during operation and

IMPORTANT

maintenance of the Forced Draft Fan, and that, if not heeded, may result in an accident of an in-assessable hazard level. “NOTICE” describes useful information and tips for operation and maintenance of the Forced Draft Fan.

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Notice

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1-2

Chapter 1

Safety

1.2.1 Definitions of “Serious Injury”, “Minor Injury”, “Serious Damage to Property”, and “Minor Damage to Property” “Serious Injury” This term describes injuries, which leave after effects such as loss of eye sight, permanent disability, bone fracture or breakage, gas inhalation, asphyxiation, electric shock, hospitalization or prolonged hospital visits for treatment.

“Minor Injury” This term describes injuries, which do not require hospitalization or prolonged attention at a hospital (injuries other than “the serious injuries” described above).

“Serious Damage to Property” This term describes damages, which require a suspension of productive activity for one day or more due to restoration of the damaged property.

“Minor Damage to Property”

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This term describes damage, which does not require any suspension of productive activity due to restoration of the damaged property.

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Chapter 1

Safety

1.2.2 Symbol In this manual, the following symbols are added for easy understanding of the contents of warnings and are found next to “DANGER”, “CAUTION” and other indications. These symbols are in compliance with “ISO 3684”. Symbol

Description This symbol indicates the possible presence of high voltage, and warns of a hazard which may result in system shock, burn or death by electric shock if safety precautions are neglected or the system is handled incorrectly. This symbol indicates a movable section that is inside a safety cover or is exposed. Movable parts may inflict laceration or bone fracture to body parts such as a hand by pinching the hand and/or clothing. This symbol indicates the presence of parts the surface of which could be hot, and may cause a burn if handled incorrectly. This symbol indicates that care should be taken where you place your feet when moving around the area. Risk of injury by tripping is present near this symbol due to factors such as a location with an unstable surface, or obstructions such as scaffolding, temporary pipe lines, or other protrusions. This symbol indicates the possible presence of gas (es) harmful or asphyxiant to personnel. Be sure to ventilate fully before work commences. This symbol indicates caution against the handling of a heavy object or working in an abnormal position. Do not work in an abnormal posture which may damage your back or waist. This symbol indicates “prohibited” items or actions during the

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operation and maintenance of the Forced Draft Fan.

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Chapter 1

1.2.2

Safety

Symbols (Continued from previous page)

Symbol

Description This symbol indicates that personnel must not touch since the surface is hot. Do NOT enter any area where this symbol is displayed.

This symbol indicates that the entry of personnel is prohibited. Do NOT enter any area where this symbol is displayed.

This symbol indicates that physical contact is prohibited. Do NOT touch or enter a location or enclosure where this symbol is displayed. This symbol indicates that the stated items or actions in the warning notices relative to operation and maintenance of the Forced Draft Fan are mandatory. This symbol indicates a movable section that is inside a safety cover or exposed. Do NOT touch any equipment where this symbol is displayed.

1.2.3 Hazard Warning Label Hazard warning labels are applied where potential hazards are present during operation and maintenance activities. Hazard warning labels will be in appropriate sizes and colors that will catch the eye and the attention of personnel. They also have symbols that show the hazard types, in addition to the descriptions of warning contents.

IMPORTANT Personnel are requested to confirm the location of, and to read, and thoroughly understand the contents of all hazard warning labels applied to this Forced Draft Fan. If any of the hazard warning labels Rev.003

peel off/wear out or become unreadable, install a new label in the

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Chapter 1

WARNING

Safety

!

DO NOT COME NEAR TO SHAFT EXPOSED ZONE WHEN IN OPERATION

PINCH POINT

STEEP DROP

DO NOT ENTER

DO NOT TOUCH

DO NOT TOUCH

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TB0001_A

FIGURE 1-1 Forced Draft Fan Mitsubishi

TYPES OF HAZARD WARNING LABELS

1-6

Chapter 1

1.2.4

Safety

Hazard Area

IMPORTANT Only trained maintainers or operators are allowed to enter the maintenance work area. Entry to the area by personnel untrained could cause not only injury but also serious damage to the Forced

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Draft Fan.

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Chapter 1

1.3

Safety

Risk Assessment Standard As prepared by the Design Section as per MIL STD822D. TABLE 1-1

RISK ASSESSMENT STANDARD Detailed Description of Impact on each Object

Category

Safety

I

Catastrophic

II

Critical

III

Marginal

VI

Negligible

- Unit shutdown (unit cannot be operated) - More than 4 days for repairing - Unit shutdown (can not be operated) - Within 3 days for repairing - Unit shutdown (can not be operated) - Can be repaired by Customer

TABLE 1-1

- Death

- Harmful gas, coal or oil leakage - High pressure and temperature material leakage such as steam, water, air and gas, oil, coal etc. - Low oxygen

- Serious Injury

- Same as the above

- Minor Injury (with hospitalization) - Minor Injury (without hospitalization)

- Same as the above - High temperature surface - High elevation or unstable - Not harmful and high pressure & temperature leakage -Mechanical protected

Description

Category

Detailed

(A)

Frequent

Repeating occurrence

1 time / 1 or 2 months

(B)

Probable

Known to occur, or, “it has happened”

1 time / 1 year

(C)

Occasional

Could occur

1 time / 5 years

(D)

Remote

Not likely to occur

1 time / 10 years

(E)

Improbable

Practically Impossible

1 or 2 times / total life

TABLE 1-1 Hazard Categories Frequency of Occurrence

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Environment

RISK ASSESSMENT STANDARD (CONTINUED)

Definition

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Health

RISK ASSESSMENT STANDARD (CONTINUED) I

II

III

VI

Catastrophic

Critical

Marginal

Negligible

(A)

Frequent

1

3

7

13

(B)

Probable

2

5

9

16

(C)

Occasional

4

6

11

18

(D)

Remote

8

10

14

19

(E)

Improbable

12

15

17

20

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Chapter 1

Safety

DANGER ZONE (Contains the high temperature & high pressure medium such as steam, water, air and gas, coal, oil etc)

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WORKING FLOOR

MPTD-3-0536

Forced Draft Fan Mitsubishi

FIGURE 1-2

FDF MAPPING FOR HAZARDOUS AREAS 1-9

Chapter 1

1.4

Safety

Safety Measures 1.4.1 Work Permit System (Lockout / Tagout) Work permit system is applied when equipment is shutdown for maintenance work, to complete the maintenance work under a safe condition. The outline of the work permit system is as follows: (1)

The Maintenance Engineer applies for the work permit clearly indicating the content of the maintenance work that he wants to do, and submits it to the Shift Charge Engineer.

(2)

The Shift Charge Engineer passes the work permit form to the operator to study and decide the isolation method from the line in operation on the mechanical and electrical view point and then report to the Shift Charge Engineer with his comments on the hazard conditions for the work.

(3)

The Shift Charge Engineer gives work permit number and prepares necessary tags to show the work permit number and the situation of isolation by valves and power supply. He will then instruct the operators to set the isolation condition following the work permit form.

(4)

The operators will open the breaker and set the valves to the specified condition, they will drain and vent the equipment to be worked on, and the breaker and the valves are then locked. The operators return the work permit to the Shift Charge Engineer.

(5)

The Shift Charge Engineer checks the isolation and will issue the signed work permit to the Maintenance Engineer, or his representative.

(6)

The Maintenance Engineer orders the start of the maintenance work to the personnel nominated.

(7)

The Maintenance Engineer or his representative will then return the signed work permit to the Shift Charge Engineer after making sure the maintenance work is completed.

(8)

The Shift Charge Engineer will then send operators to release the locks and return to the original situation.

(9)

The operators check the situation and report that the system is now back to the normal condition when signing off the work permit.

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(10) The Shift Charge Engineer makes sure that the work under the permit is completed and files details in the log book.

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The work permit system is to clarify responsibility for the works on each step and to ensure that the work is performed safely.

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Chapter 1

Safety

1.4.2 General Cautions on Personnel in Working Area 1.4.2.1

Cautions against Rotating Equipment All couplings on rotating machines are covered by the coupling cover but whole parts of the shaft are not fully covered. It is recommended that the following warning is observed strictly.

•

Do not approach or operate the equipment where protective covers have been removed. Get additional supervisor assistance.

•

Make sure that the breaker for the motor is opened when you are required to remove the cover.

•

Care must be taken of the exposed rotating parts especially in the area between the casing , the coupling and moving blades.

•

All shafting, coupling and other rotating parts must be guarded in order to prevent accidental contact.

1.4.2.2

Cautions against Electrical Equipment

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The electrical equipment covered under this section includes all the concerned plant equipment and the maintenance tools like grinders, lamps, welding equipment etc. though live parts of the plant equipment or maintenance tools are insulated; be sure to observe the following cautions. Failure to observe them may cause fatal accidents, personal injuries and damage to the electrical equipment.

Forced Draft Fan Mitsubishi

•

Always, confirm that power supply is disconnected at the up-stream side of power supply system and it is locked according to the Work Permit.

•

Do not remove or open panels or doors labeled with high voltage live part warning label not included in the Work Permit.

•

Ensure the proper earthing is provided for all electrically operated tools and equipment used for maintenance works.

•

When using lamps for internal inspection, ensure that a low voltage system (24volts) is available.

•

Make sure that no materials or Parts remain in the Panel or terminal box before closing them finally.

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Chapter 1

1.4.2.3

Safety

Cautions against High Temperature Sections Various equipment and pipelines contain high temperature steam or water in the plant, and most are insulated on their surface. There are also several hot spots in the wide area of the Plant where some specified equipment and pipe lines are not insulated, and as the temperature is quite high, you could get burned. Please observe the following cautions to avoid burn injury.

CAUTION Wear suitable working wear including gloves, to avoid direct contact to hot spots in the plant.

•

Clinkers in the boiler bottom are often very hot inside even though they look cool on the outer surface.

•

Always wear gloves in this situation.

•

Level gauges of pressure vessels including connecting pipes are not insulated to cool down the steam to drain.

•

Sampling piping is not insulated to cool down the steam to a suitable temperature for the analyzer except in the places located close to the working area for personnel.

•

All exhaust pipes of the safety valves and the exhaust pipe of the boiler flush pipe are not insulated.

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Chapter 1

1.4.2.4

Safety

Cautions for Steam Leak in the Plant The steam leak especially from high temperature steam may cause serious injury to the personnel and it must be repaired at an early stage of the leakage. The following pre-cautions must be followed to find leakage at an early stage.

•

Water drips may occur at the insulated parts such as the connected parts of the lagging. The leaking point can be found by removing insulation partially using great care.

•

As you approach the leakage, the water will change to visible steam. It is now too dangerous to remove the insulation.

•

Leakage of the superheated steam only makes whistling noise without generating white steam. It is very dangerous to approach the noise area.

•

Contact the Charge Engineer to obtain a Permit to Work before repairing the damage.

•

Be well aware of the steam. The steam could leak from the water system containing water at 100ºC or higher even if it is a low pressure type water system.

•

High temperature drain or steam could leak from the flush pipe during start-up.

•

If not avoided, the steam or vapor can enter the inside of your working wear through the small gap between the body and the clothing.

1.4.2.5 Caution against Oil / Coal Leak in the Plant

•

Oil / Coal leakage is very dangerous. It is a potential fire hazard.

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•

Any oil spillage must be reported to the Shift Charge Engineer.

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CAUTION

•

Oil leaks make the area slippery and people are advised to move around these areas carefully.

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Chapter 1

1.4.2.6

Safety

Cautions against Chemicals Pay attention to the items listed below to prevent any accident related to the chemicals in the plant.

IMPORTANT Precaution against chemicals: •

Operate chemical injection systems by strictly following the instruction of the chemist. The operator must use suitable protective tools.

Disposal: •

Observe the rules and regulation of the installation site.

Material safety data sheet (hereafter MSDS): •

Always understand the content of applicable MSDS in advance, and observe the notified instructions when handling.

Emergency response: •

Solution against emergency must be thoroughly instructed to all personnel involved so that the fullest measures can be taken against any situation.

1.4.2.7

Cautions against Combustible Materials/ Storage Areas

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IMPORTANT

Forced Draft Fan Mitsubishi

•

Storage containers must be clearly marked to indicate the content.

•

Bunding must be provided for bulk tanks.

•

Suitable fire protection must be provided for each area.

•

Do not store bulk combustible materials on the site.

•

Small quantities of combustible materials must be stored in fire resistant cupboards.

•

Combustible materials must be segregated from other equipment.

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Chapter 1

1.4.2.7

Safety

Cautions against Combustible Materials / Storage Areas (Continued)

IMPORTANT •

Leakage of gasoline has the risk of fire. Maximum storage quantity of gasoline outside of the dispensing pump is five liters.

Emergency response: •

Personnel directly involved in combustible materials MUST be properly trained and thoroughly instructed. Other personnel in the vicinity must be aware of the dangers and take precautions in all situations.

1.4.2.8

Cautions against Lack of Oxygen

Check that the oxygen content in the equipment vessel or in the confined space is between 18~22% before entering, and ensure sufficient ventilation.

•

Continue monitoring oxygen and ventilation during inspection.

•

It is recommended that you do not enter the equipment, vessel or confined space alone but if the situation demands that you must enter, take the necessary preventive safety measure provided, breathing system etc, and find a partner who will wait for your return at the point of entry, keeping in verbal contact throughout.

•

Make complete arrangements for rescue.

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1-15

Chapter 1

1.4.2.9

Safety

Cautions against Lifting Heavy Object Be careful during the removal/installation of any equipment during maintenance.

CAUTION • Do NOT attempt to move or lift equipment in an abnormal

posture. ALWAYS install/remove equipment, using a forklift or a crane. A normal lift without mechanical aid should be handled by using two or more persons. • Failure to observe the above may cause injury due to dropped

equipment, back or waist injury or damage to the equipment.

1.4.2.10 Caution against Sharp Objects

CAUTION • Use leather gloves when handling parts with sharp edges.

1.4.2.11 Cautions using Fork Lift

CAUTION • Do NOT permit anyone to stand below any item being lifted

under any circumstance. • Failure to observe this may cause fatal accidents. • When using a forklift, ALWAYS lift the objects parallel to the

ground while considering the center of gravity. • Otherwise, lifted objects may fall and serious damage could

occur. • A forklift is often used to transfer small machines. Check fork

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insertion position for the forklift prior to use. Be careful, as marks which indicate the fork insertion positions are sometimes hidden by wraps or packing materials.

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1-16

Chapter 1

Safety

1.4.2.12 Cautions using Crane

CAUTION A crane is often used to transfer heavy parts. Check for any possible risks which could occur during hoisting and transportation before operating the crane. Check of the equipment: • Check the crane, the crane hook and all related items before

use. Use wire ropes which can withstand the weight of the parts multiplied by a safety factor. • Inspect the shackles, eyebolts, jigs and wire ropes provided for

the hoisting work prior to the actual hoisting. • Perform periodical inspection (dye penetrant test) of hoisting

tools at least once a year. Rigging / Slinging work: • Only authorized personnel can perform slinging work and

operation of the crane. Work area: • Before hoisting, secure a working area around the part to be

lifted and prohibit the entry of unrelated personnel.

Hoisting method: • Hoist the part parallel to the ground while paying attention to

the center of gravity. • Do NOT permit any person to stand under the part being lifted. • Pay attention to and ensure that all persons are clear of the

equipment being lifted. Hoisting point: • Do NOT hoist any parts from a position other than the specified

hoisting points. Unpacking: • Do NOT unpack any part until it is located in the designated

location. Rev.003

Protection of machine:

MM-M02.01

• Avoid any impact to the unpacked parts.

Forced Draft Fan Mitsubishi

1-17

Chapter 1

1.4.2.13 a)

Safety

Disposal Water disposal including oily drain The water is disposed to the plant drain system. The water must be carefully disposed according to the materials contained in the water. The water drain system is separated into three categories that are rain water, chemical water and oily water. The waste waters are treated and then discharged into the public drain system.

b)

Chemical disposal Chemicals must be handled following the instruction of the MSDS and disposed to the chemical drain system.

c)

Solid disposal made by maintenance work

MM-M02.01

Rev.003

For disposal from the site, observe the local legal regulations.

Forced Draft Fan Mitsubishi

1-18

Chapter 1

1.5

Safety

Emergency Measure 1.5.1 Evacuation on Emergency Case 1.5.1.1

Evacuation Route Following items are considered on design and installation of emergency evacuation.

IMPORTANT • Each building installed in the plant is provided with at least two

exits. A clear indication of the exits can be seen from anywhere in the building as the exit sign is illuminated using the emergency power supply. • Evacuation routes are indicated on each floor of the building,

directing personnel to the exits. • Keep the evacuation routes completely free from materials and

tools.

1.5.1.2

Evacuation of Disabled Persons Who Cannot Move by Themselves The following are necessary items, prepared for emergency evacuation.

IMPORTANT • It is recommended to keep a stretcher available for

emergencies at the places selected as being secure at the safety meeting. • If you find this kind of accident, inform the rescue team, and

MM-M02.01

Rev.003

attempt to bring the collapsed person to the first aid station.

Forced Draft Fan Mitsubishi

1-19

Chapter 1

1.5.1.3

Safety

Evacuation from Power House Following are guidance for the evacuation from the power house.

IMPORTANT • An evacuation place for personnel to gather in after evacuation

from the power house in an emergency must be predetermined and explained beforehand in the emergency training. • Evacuation directive must be given by the responsible person

such as Shift Charge Engineer, and all personnel must be alerted in the power house repeatedly with an available broadcast facility. • All people working in the power house must stop their work

immediately and leave the power house to the gathering place. • When evacuated to the evacuation place, make sure

MM-M02.01

Rev.003

that there is no one missing.

Forced Draft Fan Mitsubishi

1-20

Chapter 1

Safety

1.5.2 Fire Accident

IMPORTANT • Clearly show the location of fire alarm push button and fire

extinguisher to make everybody take the first step at fire protection. • Inform everyone concerned that a fire has now started if you

discover a fire. • Start fire fighting using the fire extinguisher located near the

fire site. • The operators must check the plant is ready for trip, and wait

for order from the responsible person. • The operator and other personnel must transfer the fire fighting

to the fire fighting team when they arrive at the fire site and the operators must wait for instruction from the Shift Charge Engineer. All other personnel must immediately start evacuation. • If unit trip is decided, the operator must trip the plant manually. • The operators must evacuate from the power house according

to the instruction of the responsible person immediately after shutdown of the unit. • If the fire is extinguished successfully, the operators should

return to the power house as required by the Shift Charge Engineer and start inspection of the equipment for restart of the unit. • Based on the inspection, the responsible person should decide

whether to operate the unit again or shutdown for repairing. • After the inspection or repair, and then checking the equipment

MM-M02.01

Rev.003

and/or system, start up the unit again.

Forced Draft Fan Mitsubishi

1-21

Chapter 1

Safety

1.5.3 Earthquake In the case of an earthquake, the shift charge engineer or operator must judge whether the unit trip is necessary according to the intensity of the earthquake, and immediately trip the unit manually. If the unit is tripped, all equipment must be carefully checked on its operation status and tripped if abnormal phenomena are found. In the local area, mechanical and/or thermal shocks may be given to the equipment, piping, instruments and electrical panels. Be sure to observe the following when completing the inspection.

• Check that the lubricating oil pump is running. Bearings of the

equipment will be damaged if lubricating oil is not supplied. • Check the piping and equipment for steam and water leakage. The

steam or high temperature water leakage may cause serious injury to the personnel and it must be repaired at an early stage of the leakage. • Check the pulverizers and /or coal silos for signs of a fire. If a coal

fire does start, make sure that CO2 fire fighting system is properly operated. • Check the position of boiler seismic stopper. Since the boiler

seismic stopper must be anchored at the original position, boiler cannot be re-started if the slippage is found. If the stopper is not at the original position, please contact MHI.

CAUTION • Check the piping and equipment for breaking and the dropping of

insulation. Since the exposure of hot surface may cause burn injury, it must be repaired by a maintainer fully dressed in his personnel protective equipment.

1.5.4 Explosion Accident

Rev.003

• Do not use a fire in a hazardous area where the combustibles

MM-M02.01

(hydrogen gas, oxygen gas, coal, fuel oil, etc.) are stored or handled. Use of a fire in a hazardous area could cause serious injury to personnel and serious damage to equipment due to an explosion.

Forced Draft Fan Mitsubishi

1-22

Chapter 1

1.6

Safety

Qualification and Training The system must be operated only by authorized operators & maintenance supervisors. The customer shall authorize all operators and maintainers, who are involved in the operation and maintenance of this plant, either by the training course given by Mitsubishi, or by the customer’s own personnel assessment. Operator and maintainer training course (both classroom training and On Job Training (OJT)) will be provided by Mitsubishi before the handing over of this plant. The customer must train and assess new operators and maintainers who join after the turn-over according to his own procedure and standard, (Mitsubishi training course may still be available if required).

•

Operator and Maintainer can read and fully understand the description of this manual.

•

Operator and Maintainer can understand the related P & ID, logic diagram.

•

Operator and Maintainer know the location of the system equipment including pipe routes, valves and instruments.

•

Operator and Maintainer have fundamental knowledge of the function of each equipment.

•

Operator can operate the equipment and the system manually at local stations.

•

Operator can operate the system remotely using the DCS system.

•

Operator can respond suitably for any kind of alarm.

•

Operator knows the location of emergency exit on the power house and is available to provide first aid treatment.

•

Operator knows emergency communication system operation.

•

Operator and Maintainer, following the Charge Engineers instruction are aware of the isolation method for mechanical, electrical and instrumental equipment being prepared for safe maintenance while the unit is in operation.

•

Maintainer must also be able to handle the maintenance tools provided by the owner and those supplied by the manufacturer.

MM-M02.01

Rev.003

As a minimum, operator and maintainer must satisfy the following:

Forced Draft Fan Mitsubishi

1-23

Chapter 2

General

C h a p t er

2 General 2.1

Purpose The purpose of this maintenance manual is to provide specific information to the PAITON III Power Plant maintenance personnel regarding the maintenance of the FD Fans. Although this document will convey a good knowledge and direction regarding maintenance of the FD Fans, it is recommended that in the event of a problem not covered in the document the person responsible should seek assistance or instruction from the manufacturer.

References a)

Air & Flue Gas System Flow Diagram MHI Dwg No. 0C058-97000-2161-1A Project Dwg No. P101-51-3-00-10-B049

b)

Forced Draft Fan Lubricant And Control Oil System P& ID MHI Dwg No. N29-10M-7091 Project Dwg No. P101-51-3-BB-BG-W004

c)

Forced Draft Fan Particular Study MHI Dwg No. 0C058-97000-2161-1A Project Dwg No. P101-18-1701.03-B007

d)

Forced Draft Fan – Outline Drawing MHI Dwg No. 0C058 - N29-10P-2385 Project Dwg No. P101-50-3-BB-BG-W001

e)

Forced Draft Fan Sectional Drawing MHI Dwg No. 0C058-N29-10M-7092 Project Dwg No. P101-50-3-BB-BG-W007

f)

Overhaul Plan For Forced Draft Fan MHI Dwg No. 0C058-P97000-3371 Project Dwg No. G101-57-3-05-00-E029

MM-M02.01 Rev.003

2.2

Forced Draft Fan Mitsubishi

2-1

Chapter 2

2.3

General

Overview of the FDF Refer to Figures 2-1, 2-2, 2-3, 2-4 and 2-10. The Forced Draft Fan (FDF) is an essential equipment / auxiliary for the supply of combustion air to the steam generator. Each unit of Paiton Power Project is equipped with two FD fans. Each fan supplies 50% of the combustion air required at the Boiler Maximum Continuous Rating (BMCR) condition. The fan design parameters are based on air temperature of 25.5°C and an air density of 1.1665 kg/m³ at the fan inlet. The fan supplies combustion air to the boiler at a static pressure of 480 mmH2O (Gauge) as shown in Figure 2-1 and Figure 2-2. The FDF is a single stage axial fan with rotor moving blade pitch control. It is driven by a single speed 13.2 kV motor at a rated speed of 980 rpm. Looking from the motor NDE side, the direction of rotation of the fan is CW. The fan suction casing is bolted to the air inlet structure above the fan and is supported by a steel framework. The inlet structure consists of sections bolted together at the flanges. The top section is the air intake section and it is provided with a wire netting of stainless steel to prevent the ingress of foreign material. The suction silencer suction section along with the acoustic insulation on inside of the casing is designed to reduce the air intake noise to 85 dB (A) at 1 m distance from the equipment. The lower section is curved to direct the air into the impeller casing. The fans are located outside of the Generation Building at ground level. The fan and the motor are suitably supported on the four reinforced concrete foundations as shown in the Figure 2-2. A hydraulic mechanism regulates the pitch of the moving blades on the rotor which rotates at the design speed as shown in Figure 2-3.

MM-M02.01 Rev.003

Refer to Figure 2-10. An oil unit supplies the necessary high pressure control oil required to change the pitch of the moving blades during fan operation. Oil obtained from a connection before the control oil filter, is used at a reduced pressure, to lubricate the fan bearings. Cooling water from the Closed Circuit Cooling Water (CCCW) System is used to cool the lubricating oil flowing through the cooler.

Forced Draft Fan Mitsubishi

2-2

General

MM-M02.01

Rev.003

Chapter 2

FIGURE 2-1 Forced Draft Fan Mitsubishi

AIR & FLUE GAS P & I D

2-3

LOCAL PANEL

Chapter 2

General

OIL UNIT ACCUMULATOR

BLADE DRIVE UNIT E TRURTH N NO

N PLANT NORTH

CW

FDF 3A

CL OF BOILER

CW

A-A

FLOW

FLOW

FDF 3B

FLOW

SUCTION SILENCER

SUCTION SILENCER

FLOW

KEY PLAN

FAN SPECIFICATION FAN TYPE MOTOR

A FAN

FLOW

A

FAN FLOW RATE

Rev.003

3

m /min/FAN

FAN INLET TOTAL PRESS.

-50

mmH2O(Gauge)

FAN OUTLET STATIC PRESS.

480

mmH2O(Gauge)

FLUID TEMP. AT FAN INLET

25.5

FAN SPEED

980

FLUID DENSITY RATED MOTOR OUTPUT

MM-M02.01

AXIAL FAN 21000

1.1665 2500

o

C rpm

kg/m3 kW

MANHOLE

MPTD-3-0002

FIGURE 2-2 Forced Draft Fan Mitsubishi

FD FAN OUTLINE

2-4

Chapter 2

ITEM

50 54

52

51

CL OF M/B

1 2

8

4

FLOW

3

MOTOR SIDE

12

33 31

MOVING BLADE

2

ROTOR

3

TEFLON RING

4

CRANK ARM

5

CRANK ARM

6

SERVO CYLINDER

7

SERVO CYLINDER COVER

8

SLIDING PIECE FOR CRANK ARM

9

SLIDING PIECE FOR CRANK ARM (WITH PIN)

10

SIDE RING OF ACTUATOR DISK NUT FOR MOVING BLADE SHAFT

12

MOVING BLADE SUPPORT BEARING

19 18

13

INTERMEDIATE SHAFT

14

COUPLING SPACER

15

PISTON

16

PISTON RING

17

NUT FOR PISTON

18

MV-PACKING

19

PLATE FOR MV-PACKING

20

SLEEVE

21

COUPLING

22

NUT

23

BEARING BOX

24

RADIAL BEARING

25

THRUST BEARING

26

BEARING BOX COVER

27

SPHERICAL KEY

28

SLEEVE FOR BRG.

29

PILOT SLEEVE

30

PILOT VALVE

31

COVER

32

OIL COVER FOR PILOT LEAK

33

CONTROL OIL INNER PIPINGS

50

SUCTION CASING

51

IMPELLER CASING

52

REAR CASING

53

DIFFUSER

54

BAND FOR CASING

27

23

14

21 22 13

6

ROTATION

5

1

11

17 15 16 9

DESCRIPTION

11 10 30 32 29 7

CL OF SUCTION

53

26 28

26 24 25

MM-M02.01

Rev.003

20

General

MPTD-3-0025

FIGURE 2-3 Forced Draft Fan Mitsubishi

FD FAN SECTIONAL VIEW

2-5

General

MM-M02.01

Rev.003

Chapter 2

FIGURE 2-4 Forced Draft Fan Mitsubishi

FD FAN CUTAWAY VIEW

2-6

Chapter 2

2.4

General

Components Each FDF consists of the following components: •

Casing

•

Rotor assembly

•

Moving blade regulating mechanism

•

Main bearing assembly

•

Coupling

•

Control/lubricating oil system

2.4.1

Casing Refer to Figure 2-5. The fan casing consists of the following sections: •

suction silencer casing

•

impeller casing

•

rear casing

•

diffuser casing

The suction silencer consists of an expansion joint, sound deadening part, wire netting part and roof are bolted and seal welded. The suction silencer components are bolted and seal welded. Sound proofing insulation is provided on the internal surface of the suction casing. A blind drain pipe is provided for bottom of suction casing. For maintenance purpose a manhole is provided at the bottom of the suction casing lower part. The fan drive shaft penetrates the suction casing to connect with the electric drive motor installed outside the fan casing. The suction casing shape changes from rectangular to circular, in the direction of the flow. The impeller, rear and diffuser casing sections are provided with inner casings concentric to the horizontal axis of the fan and are supported on the outer casings with support plates. A band for casing is provided around the flanged joint of the rear casing and the diffuser.

MM-M02.01 Rev.003

Sound proofing insulation is provided for each outer casings. For the suction casing sound proofing insulation is done internally. Ladder is provided on both the impeller and rear outer casing for outage maintenance. The casing shape is specially designed to provide a streamline flow of air to the moving blades. Forced Draft Fan Mitsubishi

2-7

Chapter 2

General

All the flanged joints of the casing are provided with Neoprene rubber as a gasket. The casing shape is specially designed to provide a streamline flow of air to the moving blades. From the rectangular inlet connection, the air flows horizontally over the rotating blades. Air from the atmosphere is drawn through the wire netting into the suction casing through a silencer. It is directed towards the moving blades via a 90-degree bend. The air flows through the annular space between the inner casings and the outer casings. The diffuser is connected to the discharge duct through an expansion joint. Oil line is routed through the inner casing bottom side to the oil unit. Instrument tapping points are provided on the suction casing to facilitate the measurement of static pressure.

»

Impeller casing

The impeller casing houses of the following: •

rotor assembly

•

bearing assembly

The circular impeller casing gradually reduces in diameter in the direction of the flow. A tubular inner casing, installed within the impeller casing, houses the bearing assembly. The moving blades occupy the annular space between the tubular inner casing and the impeller outer casing. The impeller casing is horizontally split to ease maintenance activities. The annular inner circumferential surface of the impeller casing outer side which along the circumference of the tip circle of the moving blades is machined surface. The upper half of the impeller casing is bolted to the lower half for easy removal during maintenance.

»

Rear casing

MM-M02.01 Rev.003

The rear casing is of uniform diameter and is located between the impeller casing at the upstream side and the diffuser at the downstream side. The impeller casing and the rear casing are axially split, enabling maintenance access to the rotor wheel and the components of the moving blade regulating mechanism. The rear casing facilitates the routing of the moving blades operating shaft. The control oil supply and return lines to the moving blade operating mechanism are also routed through the rear casing. Forced Draft Fan Mitsubishi

2-8

Chapter 2

General

The rear casing is provided with an inner casing to protect the moving blade regulating mechanism components from damage. The rear inner casing is supported by the stationary blades around the circumference. A manhole is provided on the inner casing for inspection and maintenance of the moving blade regulating mechanism.

»

Diffusser

The diffuser is installed downstream of the rear casing and is connected to the discharge duct through an expansion joint. The diffuser section gradually increases in cross-sectional area, recovering the kinetic energy imparted by the moving blade. The diffuser is provided with an inner casing and is supported by plate at two locations. A manhole door is provided on the diffuser inner casing for the entry of personnel from the discharge duct and to carryout any inspection and maintenance of the moving blade regulating mechanism.

2.4.2 Rotor Refer to Figure 2-6. The rotor is a forged component welded to a solid shaft. The rotor is supported on the shaft at one point within the bearing box by anti-friction bearings. The motor side and fan side of the bearing box covers are provided with labyrinth seals to prevent oil leaks. The DE side of the shaft is fitted with a sleeve for facilitating installation of bearings on the shaft. The coupling half is keyed and shrink fitted to the rotor shaft end at the DE side and locked with a nut. The rotor is comprised of moving blades, the blade shafts and blade regulating mechanism. The blade shafts are supported by the moving blade support bearing and nuts. The moving blade support bearings are of the sealed type. The piston applied as blade pitch regulating servo cylinder piston is located on the rotor boss. The piston is fixed by means of a sleeve and parallel pin on one side and a nut on the other side. The servo cylinder moves axially over the piston while both parts are rotating. The axial movement of the servo cylinder is converted into rotary movement of the blades by a crank arm connecting the moving blade shaft. MM-M02.01 Rev.003

The moving blades, made of forged aluminum, are of light weight. The moving blades have a laminar flow blade profile, high efficiency and a good performance characteristic. Provision is made on the rotor for the addition of weights required for the dynamic balancing of the fan. Forced Draft Fan Mitsubishi

2-9

Chapter 2

General

2.4.3 Moving Blade Regulating Mechanism Refer to Figures 2-7 and 2-8-1, 2-8-2. The moving blade regulating mechanism regulates the blade pitch even while the fan operates at the rated speed. The moving blade regulating mechanism consists of the fixed piston mounted on the boss of the rotor shaft, the movable servo cylinder and the pilot valve. The servo cylinder and the piston rotate at the same speed as the rotor and cylinder alone is free to move axially. The cylinder cover secured to the servo cylinder has the necessary holes for the supply and return of the control oil which moves the cylinder. The pilot valve can move axially only and is located inside a sleeve secured to the inside of a servo cylinder. This pilot valve moves in and out to allow the flow of control oil as necessary to operate the moving blades. Control inner pipe (flexible hoses) on the pilot valve head enable the flow of supply and return, control oil and leakage oil through the drain cover. A pneumatically operated control drive located outside of the fan casing enables the operation of the pilot valve through a linkage mechanism. The linkage mechanism is so arranged that a 90° rotation of the control drive unit link rotates the moving blades through an angle of – 40° to +14°. A moving blade sticking detector is provided on the linkage between the control drive unit outside of the fan casing to detect any excessive load for operation of the blades.

MM-M02.01 Rev.003

The servo cylinder is a compact modular design and it is easy to overhaul. The ratio of input to output is one, yielding a good response characteristic.

Forced Draft Fan Mitsubishi

2-10

Chapter 2

General

2.4.4 Main Bearing Assembly Refer to Figure 2-9. The bearing box is supported on the inner casing of the impeller casing. The rotor can be overhung with one bearing box. The bearing box contains an antifriction cylindrical roller bearing at the fan end and two ball bearings at the motor end. The cylindrical roller bearing absorbs the radial load and the ball bearings absorb the thrust load generated by the fan work. End covers fitted on either side of the bearing box are provided with oil baffles or labyrinth seals to prevent lubricating oil leakage along the shaft from the bearing box. Lubricating oil is supplied to the bearing box through an oil supply line and distributed to bearings through internal holes on the bearing. An oil bath is provided in the bearing box by means of suitable protrusions in the lower half bearing box to match roller or ball of bearings. The lubricating oil for the bearings is supplied from a forced lubricating oil system, an external oil unit.

2.4.5 Control / Lubricating Oil System Refer to Figures 2-10. The control/lubricating oil system consists of: •

one 400 liter capacity oil tank

•

2 x 100% control oil pump, one in operations, one in standby

•

control oil pump suction strainer

•

control oil pump discharge strainers

•

lube oil duplex strainers

•

lubricating oil cooler

•

one return oil strainer

•

an accumulator (control oil)

MM-M02.01 Rev.003

The oil pumps mounted on the top of the reservoir draw oil from the reservoir through two dedicated individual suction strainers. The oil is then filtered by two 100% capacity oil filters and supplied as control oil at about 5.39~5.88 MPa for the blade regulating mechanism. An oil accumulator (pre-charge N2 pressure at 1.4MPa) installed on the control oil supply line absorbs minor pressure fluctuations.

Forced Draft Fan Mitsubishi

2-11

Chapter 2

General

Pressure reducing valves reduce the pressure of the control oil to about 0.15~0.18 MPa and supply lubricating oil to the fan bearings. The return control oil from the blade regulating mechanism is also directed to the lubricating oil supply line. The oil cooler receives cooling water from the CCCW System to cool the lubricating oil before admitting it to the bearing box. The oil reservoir is provided with a return oil filter to collect debris in the return oil. For further details, please refer to the Vendor’s manual, Appendix F.

2.4.6 Coupling Refer to Figure 2-11. The fan rotor is coupled to the drive motor with a rigid coupling.

MM-M02.01 Rev.003

The coupling consists of one intermediate shaft, two hubs (motor side and fan side), a spacer (motor side), reamer bolts and nuts.

Forced Draft Fan Mitsubishi

2-12

General

MM-M02.01

Rev.003

Chapter 2

FIGURE 2-5 Forced Draft Fan Mitsubishi

FDF CASING ASSEMBLY

2-13

General

MM-M02.01

Rev.003

Chapter 2

FIGURE 2-6 Forced Draft Fan Mitsubishi

ROTOR ASSEMBLY

2-14

General

MM-M02.01

Rev.003

Chapter 2

FIGURE 2-7 Forced Draft Fan Mitsubishi

MOVING BLADE REGULATING MECHANISM ASSEMBLY 2-15

General

MM-M02.01

Rev.003

Chapter 2

FIGURE 2-8-1 Forced Draft Fan Mitsubishi

LINKAGE MECHANISM ASSEMBLY

2-16

General

MM-M02.01

Rev.003

Chapter 2

FIGURE 2-8-2 Forced Draft Fan Mitsubishi

BLADE STICKING DETECTOR

2-17

MOTOR SIDE

Chapter 2

ITEM

29

16 17 F

F

34

33

28

33 34

31

MOTOR SIDE

23

18 10 19

32

28

DET.G E-E

C

D

4

22

1

C L OF BEARING

36

T GAS

37

VEN

A

35

OIL SUPPLY OF BEARING

D-D

B 9 MOTOR SIDE

37

26

F-F

7

41 42

39

26

30 5

ROTATION

G

D SEAT FOR VIBROMETER

T RO N IO AT

3

25

OIL LEVEL

OIL LEVEL

2 E

40

E 38

6

37

1

DESCRIPTION BEARING BOX (UPPER)

2

BEARING BOX (LOWER)

3

STOPPER

4

PLATE FOR BEARING KEEP

5

ADJUSTING RING (UPPER)

6

ADJUSTING RING (LOWER)

7

STOPPER BOLT

8

PIPE FOR RETURN OIL

9

ECCENTRIC BUSH

10

O-RING

11 12

SEAL PACKING ADJUSTING LINER

13

ADJUSTING LINER

14

ADJUSTING LINER

15

ADJUSTING LINER

16

BOLT

17

WASHER

18

SPECIAL BOLT

19

FLAT BAR

20

BOLT

21

WASHER

22

90 ELBOW

23

TAPER PIN

24

SEAT FOR THERMOMETER

General

O

25

PARALLEL PIN

26

BEARING KEEP

27

OIL BATH DRAIN PLUG

28

THRUST BEARING

29

RADIAL BEARING

30

SLEEVE

31

O-RING

32

O-RING

33

BEARING INNER SPACER

34

BEARING OUTER SPACER

35

BOLT

36

PARALLEL PIN

37

SPHERICAL KEY

38

OIL BAFFLE ASS'Y (COUPLING SIDE)

39

OIL BAFFLE ASS'Y (ROTOR SIDE)

40

SHAFT

41

BOLT

42

WASHER

A

MM-M02.01

Rev.003

B-B

C C-C

12 13 14 15

B 11 A-A

OIL RETURN OF BEARING

20 21 27

24

27

MPTD-3-0037

FIGURE 2-9 Forced Draft Fan Mitsubishi

BEARING BOX ASSEMBLY

2-18

Chapter-2

FT

FT

FT

PT

TE

1

2

3

1

2~4

General

FDF SUCTION SILENCER

TI TE 25A

10A

65A

15A

15A 20A 15A 15A 20A

25A

PI 40A

40A

DPI PT FT XE PS

LUBRICATING OIL RETURN

BLADE STICKING DETECTOR

20A

PILOT LEAK OIL

20A

ZS 2

OIL SEAL LEAK OIL

ZS

U-SEAL

LS LI

U-SEAL CONTROL OIL LEAK OIL

20A

20A

25A

40A

25A

PS 1

FOR MAINTENANCE

PS 6 PS 5 PS 4 65A

PS 2

LOCAL PANEL

20A

PS 3

LUBRICATING OIL SUPPLY

A-1

FOR MAINTENANCE

25A

ZS 1

CONTROL OIL SUPPLY

DU-1

CONTROL OIL RETURN

40A

F-4

PI 2

PI 1

F-6

PI 4 03HLB01AC1 C-1

WATER DRAIN

P AIR BREATHER

TI 1

M P 03HLB01AP202 P-2

(03HLB01AP204)

LS 1

PI 5

TI 3

OIL SUPPLY PLUG

F-1 LI 1

T-1 03HLB01BB101 (03HLB01BB102) F-3

50A

50A

40A

MM-M02.01

Rev.003

OIL UNIT

SET POINT

5.39 ~ 5.88 MPa

0.15 ~ 0.18 MPa

RANGE 0~15MPa 0~15MPa 0~15MPa 0~1.0MPa 0~1.0MPa 0~0.4MPa

SYMBOL PI-1 PI-2 PI-3 PI-4 PI-5 PI-6

03HLB01CP211 (03HLB01CP221) 03HLB01CP212 (03HLB01CP222) 03HLB01CP213 (03HLB01CP223) 03HLB01CP214 (03HLB01CP224) 03HLB01CP215 (03HLB01CP225) 03HLB01CP216 (03HLB01CP226)

CONTROL OIL PRESS. NORMAL INTERLOCK

03HLB01CT311 (03HLB01CT321) 03HLB01CT312 (03HLB01CT322) 03HLB01CT313 (03HLB01CT323) 03HLB01CT314 (03HLB01CT324)

FDF LUBRICATING OIL COOLER INLET FDF LUBRICATING OIL COOLER OUTLET COOLING WATER INLET OIL TANK

03HLB01CT011 (03HLB01CT021) 03HLB01CT001 (03HLB01CT051) 03HLB01CT002 (03HLB01CT052) 03HLB01CT003 (03HLB01CT0530

BEARING OIL TEMPERATURE HIGH ALARM FDF 3A/3B SUCTION AIR TEMP.-A FDF 3A/3B SUCTION AIR TEMP.-B FDF 3A/3B SUCTION AIR TEMP.-C

03HLB01CY011 (03HLB01CY021)

BEARING VIBRATION HIGH ALARM

03HLB01CG211 (03HLB01CG221) 03HLB01CG212 (03HLB01CG222)

BLADE ANGLE 0% POSITION INTERLOCK BLADE STICKING ALARM

FULL CLOSE ON

ZS-1 ZS-2

03HLB01CG211 (03HLB01CG221) 03HLB01CG212 (03HLB01CG222)

OIL TANK LEVEL LOW ALARM

MIN. OIL LEVEL LOWER THAN 50mm (122 ) ON

LS-1

03HLB01CL311 (03HLB01CL321)

OIL TANK LEVEL

MAX. OIL LEVEL 400 MIN. OIL LEVEL 170

LI-1

03HLB01CF101 (03HLB01CF151) 03HLB01CF102 (03HLB01CF152) 03HLB01CF103 (03HLB01CF153)

FDF 3A/3B AIR FLOW-A FDF 3A/3B AIR FLOW-B FDF 3A/3B AIR FLOW-C

03HLB01CP101 (03HLB01CP151)

FDF 3A/3B SUCTION PRESS.

CONTROL OIL PRESS. LOW TRIP LUBRICATING OIL PRESS. NORMAL INTERLOCK LUBRICATING OIL PRESS. LOW TRIP

0~10MPa P> = 4.90 MPa ON 0~10MPa P< = 4.41 MPa ON < 1.96 MPa ON 0~10MPa P= > 0.13 MPa ON 0.02~0.2MPa P= < 0.12 MPa ON 0.02~0.2MPa P= < 0.08 MPa ON 0.02~0.2MPa P=

PS-1 PS-2 PS-3 PS-4 PS-5 PS-6

0~100 C 0~100 C 0~100 C 0~100 C

TI-1 TI-2 TI-3 TI-4

T> = 70 C ON

0~150 C

TE-1 TE-2 TE-3 TE-4

V> l ON = 105um

0~300um(P-P) l

XE-1

EQUIPMENTS LIST SYMBOL

TI 4

F-2

03HLB01CP311 (03HLB01CP321) 03HLB01CP312 (03HLB01CP322) 03HLB01CP313 (03HLB01CP323) 03HLB01CP314 (03HLB01CP324) 03HLB01CP315 (03HLB01CP325) 03HLB01CP316 (03HLB01CP326)

DESCRIPTION FDF CONTROL OIL PUMP 3 A1/B1 OUTLET FDF CONTROL OIL PUMP 3 A2/B2 OUTLET CONTROL OIL SUPPLY PRESS. FDF LUBRICATING OIL COOLER INLET FDF LUBRICATING OIL COOLER OUTLET LUBRICATING OIL SUPPLY PRESS.

TI 2

OIL DRAIN

03HLB01AP201 (03HLB01AP203)

P-1

20A

PI 6

F-5

M

65A

25A

PI 3

40A

25A

25A

THERMOMETER (LOCAL) THERMOCOUPLE PRESSURE GAUGE (LOCAL) DIFFERENTIAL PRESSURE GAUGE PRESSURE TRANSMITTER DIFFERENTIAL PRESSURE TRANSMITTER VIBRATION METER PRESS. SWITCH LIMIT SWITCH LEVEL SWITCH LEVEL GAUGE GLOBE VALVE GLOBE VALVE (NORMALLY CLOSED) REGULATING VALVE SAFETY VALVE 3-WAY VALVE STOP CHECK VALVE BUTTERFLY VALVE NEEDLE VALVE REDUCER SIGHT FLOW STRAINER OIL COOLER ORIFICE ACCUMULATOR CHECK DAMPER FLANGE EXPANSION JOINT FLEXIBLE HOSE CAP OIL LINE DRAIN LINE COOLING WATER LINE AIR LINE CAPILLARY ELECTRIC SIGNAL AIR SIGNAL

PRESSURE GAUGE

MOTOR

INSTRUMENTS LIST

PRESSURE SWITCH

FDF

EXPLANATION OF SYMBOL DESCRIPTION INSTRUMENT(FIELD MOUNTED) LOCAL PANEL MOUNTED INSTRUMENT

THERMOMETER

SYMBOL

THERMO COUPLE

03HLB01AN101 (03HLB01AN102)

LEVEL LEVEL LIMIT GAUGE SWITCH SWITCH

15A

TE 1

15A

03HLB01BS101 (03HLB01BS102)

XE 1

P-1 P-2 F-1 F-2 F-3 F-4 F-5 F-6 C-1 A-1 T-1 DU-1

DESCRIPTION FDF CONTROL OIL PUMP 3 A1/B1 FDF CONTROL OIL PUMP 3 A2/B2 RETURN OIL STRAINER

LUBRICATING OIL DOUPLEX STRAINER FDF LUBRICATING OIL COOLER ACCUMULATOR OIL TANK DRIVE UNIT FORCED DRAFT FAN FDF MOTOR

REMARKS 7.85 MPax 34.5 /min AC 416 V x 50 Hz 7.5 kW x 6P

100 mesh 150 mesh 150 mesh 20u l 20u l 200 mesh 3 TON/Hr 60 400 Torque 102 N-m 21000 m3/minx480 mmH2O 2500kW x 6P

COOLING WATER

FIGURE 2-10

FDF LUBE AND CONTROL OIL P & I D

MPTD-3-0026

Forced Draft Fan Mitsubishi

2-19

Chapter 2

ITEM 1 2 3 4 5 6 7

6

General

DESCRIPTION MOTOR COUPLING SPACER REAMER BOLTS REAMER BOLTS NUT WIRE INTERMEDIATE SHAFT

A-A

FAN SIDE

6

5

MOTOR SIDE

3

4

A

7

A

2

5

6

1

A

A

PUT MATCH MARKS

PUT MATCH MARKS

MM-M02.01 Rev.003

MPTD-4-0036

FIGURE 2-11

Forced Draft Fan Mitsubishi

INTERMEDIATE SHAFT AND COUPLING ASSEMBLY

2-20

Chapter 3

Specifications

C h a p t er

3 Specifications TABLE 3-1

FORCED DRAFT FAN

Subject

Specifications

Equipment number

03HLB01AN101 03HLB01AN102

Quantity

Two (2)

Fan

Coupling Bearing

Manufacturer

MHI

Model

ML-H1-R132/270

Type

Axial Fan, Variable Blade Control

Manufacturer

MHI

Type

Rigid Coupling

Manufacturer

J TEKT

Type

Anti-friction bearing (MHI special type) Bearing No.

Major material

MM-M02.01

Rev.003

Weight (approximately)

Forced Draft Fan Mitsubishi

Basic load rating (kN) Dynamic

Static

NJ338AF3C3 +DP30-1

987

1260

7338B/1DAD T/30-1

1170

4220

Casing

Rolled Steel for General Structure

Moving Blade

Forged Aluminum

Rotor Shaft

Carbon Steel for Machine Structural Use

Bearing (Box/Body)

Cast steel

Coupling

Cast steel

Silencer

33.0 t (including expansion joint)

Rotor assembly

3.0 t

Suction Casing

17.0 t (including insulation)

Impeller Casing – Upper Half

2.0 t (included insulation)

Impeller Casing – Lower Half

3.0 t (without insulation)

Rear Casing – Upper Half

1.3t (included insulation)

Rear Casing – Lower Half

1.4 t (without insulation)

Diffuser

7.6 t (without insulation)

3-1

Chapter 3

Specifications

Continued form previous page

TABLE 3-1

FORCED DRAFT FAN

Subject

Specifications

Design Rotating Speed

980 rpm

Blade

14

Performance Characteristics Direction of Rotation

Clockwise (Viewed from motor side)

Capacity (each fan)

21,000 m3/min

Inlet pressure

-50 mmH2O

Outlet static pressure

480 mmH2O

Fluid

Air

Fluid temperature at inlet

25.5° C

Fluid density (design)

1.1665 kg/m3

TABLE 3-2

FORCED DRAFT FAN - MOTOR

Subject

Specifications

Manufacturer

Hyundai Heavy Industries Co. Ltd.

Type

HRP3 637-68E

Rated Output

2,500 kW

Rated Voltage

13,200 V

Rated Current

133.1 A

Frequency

50 Hz

Poles

6

Coupling

Direct

Rating

Continuous

Insulation Class

F

Maximum Ambient Temperature

40° C

Bearing

Split sleeve

Type

14,500 kg

MM-M02.01

Rev.003

Total Weight (approximately)

Forced Draft Fan Mitsubishi

3-2

Chapter 3

TABLE 3-3

Specifications

FDF CONTROL OIL UNIT

Subject

Oil Specification

Specifications

ISO VG 32

Electric Power

Power

AC 380V, 7.5kW, 1,000rpm

Control Oil Pump

Type

Vane Pump

Quantity

Two (2) sets (1 Normal ; the other for stand-by)

Capacity

34.5L/min

Working Pressure

7.85 MPa

Type

Totally Enclosed Fan Cooled Type

Quantity

Two (2) sets

Oil Tank

Total Volume

400 l

Oil Cooler

Type

Shell and Tube

Quantity

One (1) set

Water quantity

3.0 Ton/H

Oil Pump Motor

150 mesh

Return Oil Strainer

100 mesh

Lub. Oil Pump – Discharge duplex strainer

200 mesh

Control Oil Pump – Discharge Strainer

20 μ

Accumulator

60 l

MM-M02.01

Rev.003

Suction Strainer – Control oil system

Forced Draft Fan Mitsubishi

3-3

Specifications

MM-M02.01

Rev.003

Chapter 3

FIGURE 3-1

Forced Draft Fan Mitsubishi

PEFORMANCE CURVE

3-4

Chapter 4 Preventive Maintenance

eu

C h a p t er

4 Preventive Maintenance Preventive maintenance is carried out to avoid or minimize the possibility of failure or deterioration of equipment performance. This requires a constant effort from maintenance staff to ensure that the Unit is available on demand. There are two categories of preventive maintenance, Routine Maintenance and Annual Outage Maintenance. Routine maintenance helps to reduce the possibility of outage and hence the downtime of machinery. Annual outage maintenance is required to maintain the internal components of the installed equipment. Though vendor/manufacturer’s recommendations provide a good basis for the provision of a preventive maintenance schedule, the frequency and other details should be updated from time to time based on practical experience and actual feedback gathered through inspection and normal operation of the equipment/plant. Consideration of these site related specific issues will make the preventive maintenance more effective.

4.1

Prerequisites The necessary prerequisites for the preventive maintenance of the FDF are as follows:

4.1.1 Scheduling Scheduling is the first activity in the preparation of a preventive maintenance program. The schedule is to include planning to attend all operating equipment on a fixed regular basis. Initially, schedules will be prepared based on vendor/manufacturer’s generic instructions, the schedules will, however, be updated (frequency, nature of inspection, etc.) as site specific data becomes available.

Rev.003

Preventive maintenance is to be coordinated with other concerned departments. In the case of a major scheduled outage, maintenance personnel and other concerned departments should jointly produce a plan of activities, well in advance, to decide the inspection activities and other logistics (such as the availability and supply of required equipment, spare parts, and tools, etc.).

MM-M02.01

The schedule should clearly identify the critical path. Priority is to be assigned to specific tasks that also involve parallel activities to reduce the equipment downtime and to complete the work within the scheduled time. Forced Draft Fan Mitsubishi

4-1

Chapter 4 Preventive Maintenance

4.1.2 Departmental Interface/Notification Departmental communication is essential and interfacing between departments is to be maintained to avoid any lack of communication that may arise and adversely affect routine or annual outage maintenance work. Prior to commencing preventive maintenance all concerned persons (shift supervisor, operators, etc.) are to be made aware of the schedule and the nature of the activities that are to take place. If it becomes clear that there is a problem or a conflict of interests in the schedule (e.g. the maintenance schedule interferes with another group’s work, inter departmental works, sub contractors work etc.), this is to be resolved by mutual agreement between the parties involved.

4.1.3 Isolation of Equipment It is important that isolations are agreed and valid clearances and work permits are obtained before any maintenance work is performed. The isolation boundaries of the particular equipment to be taken under maintenance are to be clearly identified. In the case of an electrical isolation the power supply shall be disconnected and/or the fuses removed. In the case of a mechanical isolation, the valves or other mechanical means of isolation, at the isolation boundaries are to be closed and if possible locked closed. The system within the isolation boundaries is to be vented and depressurized.

4.1.4 Safety Precautions Before the commencement of any maintenance work, the person in charge of the work site is to perform a risk assessment and method statement for the safe execution of the job scope activities, described within the work permit. Risk assessment includes identifying, recognizing and understanding the potential hazards associated with the work. The method statement is to illustrate the safe working practices in accordance with the safety manual and the manufacturer’s instruction manual to prevent personal injury and/or equipment damage.

Rev.003

Prior to the commencement of actual work, the person carrying out the work is to make a safety check based on the above method statement and also use his own judgment to ensure that the equipment and the prevailing working conditions are safe.

MM-M02.01

During maintenance work, every employee should follow the safe working procedures detailed in the method statement. Forced Draft Fan Mitsubishi

4-2

Chapter 4 Preventive Maintenance

4.2

Routine Maintenance The purpose of routine maintenance is the implementation of the preventive maintenance program on a day-to-day basis through a planned and correctly executed inspection. The routine maintenance activities are very important in that if they are properly carried out, they will enhance equipment reliability. As a result, good routine maintenance activities may help in cost reduction in the long run through the minimization of equipment downtime. Cleaning is an important and necessary maintenance activity to prevent the ingress of foreign material. Other major points are as follows: (Summarized major routine activities are also shown in Table 4-1).

4.2.1 Preparation a)

Spare parts, Tools and Equipment It is important to prepare the necessary parts, tools and equipment before commencing actual work. Routine maintenance generally requires a standard mechanical toolkit, consumables, cleaning materials, etc. Any shortages of these items will affect the maintenance activity and may delay the schedule. Personal Protective Equipment (PPE) is necessary for maintenance staff at all times. Maintenance work area must be barricaded showing the necessary warning signs. Upon completion of work, all tools and equipment should be serviced and stored correctly to ensure availability for further use.

b)

Documentation Documentation is an important part of any maintenance duty. All findings should be noted on a comprehensive log sheet, reporting all aspects of the equipment observed during the routine inspection. The data recorded in these documents will be useful in determining the root cause of equipment failure found during annual outage/corrective maintenance work.

MM-M02.01

Rev.003

Any abnormalities, if observed, are to be immediately communicated to the concerned department/personnel for rectification and are to be detailed in the report and the value recorded every time.

Forced Draft Fan Mitsubishi

4-3

Chapter 4 Preventive Maintenance

4.2.2 Inspection and Maintenance

•

Take care near rotating machinery, hands, feet, and clothing can be drawn into machinery. Always check that all guards are in place before starting any rotating machinery.

•

No open flames or other source of ignition permitted in fan area.

•

Don’t come closer around the suction silencer inlet less than 2 m.

CAUTION •

Don’t open the manhole when fan is running.

•

Check that instruction is clear when fan is running.

•

Don’t climb on casing when fan is running.

a)

Rotor Assembly The rotor assembly, consisting of the rotor, the moving blades and the rotor shaft, etc. is to be monitored for vibration. Vibration may be generated by several factors. Possible causes of vibration are an imbalance of the rotor resulting from erosion or damage to the rotor by foreign materials, or by dust adhering to the impeller blades. Another possible cause of vibration could be shaft misalignment. If the vibration is observed to have increased, but is still within the limit of 105 µm without any other abnormality noticed, the equipment may continue to be operated under close supervision. If vibration alarm announced, look over the vibration and incase of vibration increasing, stop the fan immediately. As well as vibration, another area that deserves attention is the identification of any abnormal noise. Any abnormal noise generated should be investigated to identify the source. If the noise comes from the flange joints, e.g. high noise created by air leakage from the packing, operation may be continued, as it has no direct impact on possible fan failure or operation.

MM-M02.01

Rev.003

However, if any abnormality is observed at the coupling, the equipment is to be shutdown immediately for rectification of the problem.

Forced Draft Fan Mitsubishi

4-4

Chapter 4 Preventive Maintenance

b)

Bearings Bearing problems generally result from lubricating oil starvation and/or excessive vibration. Emphasis is to be given to check the equipment operating parameters, (e.g. oil supply, oil temperature, bearing temperature and oil tank levels). The temperature of the returning lubrication oil from the bearing is alarm value of 70°C. Correct oil flow is to be verified through the lubricating oil return line oil flow indicator. Lack of cooling water flow, fouling of oil cooler tubes, presence of dirt in the lubricating oil, deteriorated bearings may also lead to an increase in bearing operating temperature. Entering foreign materials leads to bearing damage. Using un-recommend oil leads to a poor bearing performance.

c)

Moving Blade Regulating Mechanism The moving blade regulating mechanism is to be monitored for smooth operation. Visual inspection of the linkage mechanism is to be carried out for looseness of pins and links. Operational availability of blade sticking detector is to be ensured. If there is any sign of linkage mechanism sticking, the cause should be eliminated at the earliest opportunity depending upon the severity of the problem. See Chapter 6 Corrective maintenance for reference.

CAUTION Don’t come closer to drive unit and moving blade sticking detector.

d)

Fan Casing The fan casing is to be checked for leakage. Erosion, abrasion or cracking may occur in the casing during fan operation. In the event of air leakage through any part of the casing, external patch welding work may be undertaken as a temporary measure and the event should be recorded for inclusion in the annual overhaul program.

Rev.003

e)

Control/Lubricating Oil System

MM-M02.01

The oil pump is to be monitored for smooth operation, seal leakage and vibration. Any apparent problem is to be immediately resolved.

Forced Draft Fan Mitsubishi

4-5

Chapter 4 Preventive Maintenance

The condition of the control oil / lube oil filter is to be monitored. When there is a high differential pressure across a filter the stand by filter should be placed in service and the defective filter, should be cleaned or replaced immediately to be an effective standby. It is most important to follow the lubricating oil requirements such as, the frequency of replacement of the lubricating oil as per the manufacturer’s instruction or based on the analysis result received from the laboratory. Regular visual inspection of the oil condition is recommended, (e.g. if the color of the oil becomes green/white, it signifies that water ingress has taken place. Alternately, if the oil gradually becomes dark, it implies that either overheating or debris/dirt mixing has taken place). The tank oil level is to be monitored at frequent intervals. The system is to be observed for any oil leakage if a gradual decrease in oil level is noticed. The oil flow through the return line flow indicator is to be monitored regularly. If there is an abnormal decrease or increase in return oil flow, the cause is to be investigated and rectified. If oil leakage is found, inspect the oil level gauge every time. And repair them after reducing oil pressure, if it is possible to stop the fan.

CAUTION •

If oil leakage is found, take care not to come close the leakage point because workers can get oil in the eyes.

•

Don’t go up on the piping not to damage the piping. The temperature of oil in the tank should be observed on a routine basis. The temperature should be below 70˚C. For further details, please refer to the vendor’s manual in Appendix F.

f)

Coupling

MM-M02.01

Rev.003

The fan coupling is to be monitored for any abnormal noise. Noise would be heard from the coupling if there is any looseness of the coupling bolts or coupling. Noise is also generated if the coupling misalignment is beyond permissible limits or if the coupling rubs the coupling guard.

Forced Draft Fan Mitsubishi

4-6

Chapter 4 Preventive Maintenance

TABLE 4-1

No.

1

Description

Main Bearing

ROUTINE MAINTENANCE CHECKLIST

Major Check Item

Check Method

Check Reference

Vibration

Permanent instruments

Less than 105 µm

Temperature

Permanent instruments

Not exceeding 70°C

Action to be Taken (if beyond acceptable limit)

Remarks

Recommended Maintenance Frequency

Shut down and check for bearing damage and the rotor assembly for unbalance. Check and clean the moving blades for any deposits. Check and adjust alignment.

Daily

Check for any foreign materials in the lubricating oil Rotate the rotor assembly by hand and observe for any rubbing noise. Replace bearings if the vibration is not decreased after field balancing. 2

Moving Blade Regulating Mechanism

MM-M02.01

Rev.003

3

Coupling

4

Casing

Forced Draft Fan Mitsubishi

Abnormal noise

Audible

No abnormal noise.

Check and replace coupling bolts, etc., if damaged and then re-check alignment.

Rubbing contact with the coupling guard

Visual and audible

No contact between the coupling and coupling guard.

Adjust coupling guard clearance.

Control oil pump discharge strainer

Visual

Not Clogged

Replace the clogged filter.

Smooth operation

Permanent instrument

No alarm

Visual and audible

No apparent air leakage

Check for any air leakage

Beware of rotating part during maintenance

Daily

Daily

Permanent instruments Rectify defective regulating mechanism and linkage mechanism after shut-down if FDF cannot be controlled. Tighten bolts or patch weld after shutdown.

Daily

Daily

4-7

Chapter 4 Preventive Maintenance

Continued from previous page… TABLE 4-1

No.

Description

5

Lubricating oil system

Major Check Item Check Method

Oil pressure

Permanent instrument

ROUTINE MAINTENANCE CHECKLIST

Check Reference

Lube oil supply is 0.15 to 0.18 MPa.

Action to be Taken (if beyond acceptable limit)

Remarks

Recommended Maintenance Frequency

Check the lube oil pump discharge pressure and by For more details, Please refer sight glass. to Vendor’s Manual. Check the oil flow into the bearing, pressure control valve. Check oil temperature. Check Oil flow.

MM-M02.01

Rev.003

Check the operation of the stand by pump. Oil pump bearing temperature

Touch/ Portable No appreciable thermometer temperature rise

Check the cause of temperature rise.

Oil pump shaft oil leak

Visual

No leak

Replace oil seal

Oil pump shaft rotating condition

Visual Audible

No abnormal noise No abnormal trembling

Investigate and take action to normalize the condition such as exchange of bearings.

Oil strainer

Permanent instrument

Not clogged Color indicator on the top of the strainer is not red (replacement) , but green (normal)

Change over the stand by control oil pump line and replace the clogged up strainer. (Control oil pump discharge strainer)

(Control oil discharge strainer)

Forced Draft Fan Mitsubishi

Daily

Change over the stand-by strainer and clean the blocked filter in maintenance filter (lubricating oil duplex strainer).

4-8

Chapter 4 Preventive Maintenance

Continued from previous page… TABLE 4-1

No.

Description

5

Lubricating oil system (Cont)

Major Check Item Check Method

Oil strainer

Permanent instrument

ROUTINE MAINTENANCE CHECKLIST

Check Reference

Diff. press. Less than 0.1 MPa (Lubricating oil duplex strainer)

Level gauge

Oil tank Oil temperature

Rev.003

Oil cooler water flow

Action to be Taken (if beyond acceptable limit)

Recommended Maintenance Frequency

Change over the stand by control oil pump line and replace the clogged up strainer. (Control oil pump discharge strainer) Change over the stand-by strainer and clean the blocked filter in maintenance filter (lubricating oil duplex strainer).

Visual

No leak

Exchange of O-ring Further tightening

Permanent instrument

Normal Oil Level

Investigate and top up the oil level.

Permanent instruments

Not to exceed 70ºC.

Investigate and take action to reduce the temperature

Visual,

Rated flow

Investigate and normalize the flow.

Daily

Repair of any leakage of water into the system.

Further details, please refer to Daily Vendor’s manual.

Permanent Instrument Visual

Remarks

No leak of water or oil

Further tightening

MM-M02.01

Exchange of packing. Visual, Permanent Instrument

Forced Draft Fan Mitsubishi

Oil temp. of oil cooler outlet is not to exceed 70ºC.

Cooling water check Disassembly & clean up of cooler.

4-9

Chapter 4

4.3

Preventive Maintenance

Annual Outage Maintenance The purpose of annual outage maintenance is the implementation of a preventive maintenance program on a yearly basis through a planned and correctly executed maintenance work program accompanying necessary inspections. The annual outage maintenance activities are very important in the sense that if properly undertaken these enhance the life and reliability of equipment. Major activities related to annual outage maintenance are as follows: (Summarized major activities for annual outage maintenance are also shown in Table 4-2).

4.3.1 Preparation a)

Parts, Tools and Equipment Refer to Subsection 4.2.1 a) Spare Parts, Tools and Equipment. In addition, it will be necessary to identify and request the provision of any spare part requirements. Annual outage will, in certain cases, require the use of material handling equipment. Unused spare parts are to be returned for correct storage and used spare parts are to be replenished.

b)

Documentation Refer to Subsection 4.2.1 b), Documentation. Records are to be maintained to record information regarding the spares and consumables used. These records will be used for future reference and spare parts replenishment.

MM-M02.01

Rev.003

On completion of annual outage maintenance work, the equipment is to be monitored for correct operation and maintenance data logging. This will help to determine the correct intervals of preventive maintenance activities to ensure optimum plant availability. The correct recording of findings during inspection will build a valuable document for future reference.

Forced Draft Fan Mitsubishi

4-10

Chapter 4

Preventive Maintenance

4.3.2 Inspection and Maintenance a)

Rotor Assembly The rotor assembly is to be checked for erosion, and for the adhesion of dust that could have occurred during normal operation of the equipment, either of which could induce severe rotor imbalance resulting in excessive vibration of the rotating assembly, and could cause serious equipment damage. The occurrence of wear and cracking is to be further checked through a non-destructive testing procedure (e.g. dye penetrant test, etc.). The rotor clearances with the respective stationary parts are to be checked against the tolerances as indicated in Figure 4-1, FDF Clearance Details. After thorough inspection, if any part is found to be worn beyond the acceptable limits as specified in the annual outage maintenance check list table (Table 4-2), the respective part is to be replaced. The moving blades are to be operated for full opening and closing positions to ensure that all moving blades move in unison. The support bearing of any sticking blade is to be inspected and replaced if found defective. The grooves /bosses on the rotor shaft corresponding to the bearing box oil baffle assemblies on both motor side and fan side are to be inspected for damage or wear. Minor damage can be corrected with an oilstone.

b)

Bearings Replace the fan bearings if they surpass the recommended replacement period or if they show indications of wear during operation. Operation with damaged bearings can have serious consequences in that it may induce excessive vibration and bearing temperature problems that may cause subsequent damage to the shaft.

Rev.003

To maintain the bearings in good condition the lubricating oil in the tank is to be analyzed for oil properties in a laboratory at frequent intervals and replaced in its entirety when there is deterioration in oil quality.

MM-M02.01

Prior to disassembly, the bearing box is to be inspected for any trace of oil leakage through the shaft. After disassembly, check the clearance between the oil baffle assemblies and the rotor shaft. Forced Draft Fan Mitsubishi

4-11

Chapter 4

Preventive Maintenance

Any damage to the grooves of the rotor shaft and the corresponding oil baffle assembly on the bearing box end covers is also to be checked. Check the tightness of the bearing box fixing bolts. A loose bearing box may induce vibration which could damage the fan internals.

c)

Moving Blade Regulating Mechanism Prior to dismantling, the moving blade regulating mechanism is to be inspected for any trace of oil leakage from the hydraulic cylinder and pilot valve head that might have occurred during normal operation. The inner surface of the hydraulic cylinder and the outer surface of the piston are to be checked for any damage, pitting or scratch. Minor damage can be polished with an oilstone under MHI supervision. The piston rings and the hydraulic cylinder packings are to be inspected for damage and replaced with new if found defective. The flexible oil hoses connecting the pilot valve are to be inspected for ageing, damage or cracks. Defective hoses are to be replaced with new. Correct tightening of the bolts and nuts for the linkage assembly and the greasing of the various moving parts is to be performed. On completion of the maintenance work the linkage assembly is to be checked for smooth operation with the power cylinder. The 90° movement of the power cylinder lever is to be adjusted for the moving blade operation range of – 40° to + 14°.

d)

Casing The fan casing is to be inspected internally to check for erosion, wear and cracks, and any previously reported defects are to be investigated and repaired by patch-welding. However, if wear or erosion occurs repeatedly in any particular area, the welding of a wear plate in position should be considered as a solution to the problem. Checks for corrosion are to be performed at this time.

MM-M02.01

Rev.003

Any corrosion encountered is to be removed and the resultant bare metal treated. Any accumulation of debris is to be collected and removed.

Forced Draft Fan Mitsubishi

4-12

Chapter 4

e)

Preventive Maintenance

Control / Lubricating Oil System The oil pump components such as casing, gears, bearings, oil seals, fasteners, etc. are to be inspected for any damage and the defective components replaced with new. The control oil filters are to be inspected for any deformation or damage. If there is any damage to filters, they must be replaced. The accumulator bladder is to be inspected for ageing, cracks or rupture. A defective bladder is to be replaced with new. The pre-charge pressure of the oil accumulator is to be checked and pressure readjusted using nitrogen gas. A falling pre-charge pressure is to be investigated and the defective components replaced. The lubricating oil cooler is to be inspected for tube damage or blockage. Hydraulic testing of the cooler is to be conducted and any leaking tube is to be plugged. Replace the tube bundle set with a new one if the cooler performance deteriorates after plugging several tubes. For further details, please refer to the vendor’s manual in Appendix F.

f)

Coupling

MM-M02.01

Rev.003

Coupling alignment checks are to be conducted carefully both before dismantling and after reassembly, (refer to Appendix D). Check the coupling bolts, hubs and spacer for damage or wear. Defective components are to be replaced with new. Check and confirm the security of the hubs on the respective shafts.

Forced Draft Fan Mitsubishi

4-13

Chapter 4 Preventive Maintenance

TABLE 4-2 No. 1

2

Description Rotor 1 (inc. shaft* )

Moving Blades

Major Check Item

Check Method

Check Reference

ANNUAL OUTAGE MAINTENANCE CHECK LIST Action to be Taken (if beyond acceptable limit)

Remarks

Wear, cracks

Visual

No appreciable wear No crack

Replace the rotor Every rotor overhaul assembly (4 years) Repair and rebalance *1 every bearing overhaul (every 8 years) (if have spares), 4 years (if have not spares)

Inner casing and seal clearances

Measurement

Clearances are within specified criteria (Refer to Figure 4-1)

Adjust clearance by adjusting of bearing box position (using by shim plate, etc)

Outer casing clearances

Measurement

Clearances are within specified criteria (Refer to Fig 4-1)

Adjust clearance

Wear, crack

Visual*1, Measurement *2 PT check*2

Wear less than 10%

Replace the blades

Inspection Date

Inspector

Results

Every casing overhaul (4 years) Adjusting clearance carried after checking of correct rotor assembling.

Blades are to be replaced as a set. *1. Every inner inspection (2 years) *2. Every rotor overhaul (4 years)

No crack

Moving Blade Replacement Bearing

Visual

Not loose (in caulked condition)

Tighten the blade fixing bolts and caulk

N/A

N/A

Replace

Every rotor overhaul (every four years)

MM-M02.01

Rev.003

Axial movement

Forced Draft Fan Mitsubishi

4-14

Chapter 4 Preventive Maintenance

(Continued from previous page)

TABLE 4-2 No. 3

4

Coupling

Major Check Item

Check Method

Check Reference

Action to be Taken (if beyond acceptable limit)

Visual

No defective parts

Alignment

Measurement

Refer to Appendix Realign within D specified criteria

Every coupling overhaul (4 years)

Rubbing with the coupling guard

Visual and Audible

No contact between the coupling and coupling guard

Adjust the coupling guard position

Every coupling overhaul (4 years)

Main Bearing

N/A

N/A

N/A

Replace

Clearance check is carried out when replace the bearing. Recommended to replace bearing every 8 years (if have spares), 4 years (if have not spares)

Bearing box

Seal clearance Measurement measurement

Clearance are within specified criteria (Refer to Figure 4-1)

Replace

Every rotor overhaul (every 4 years)

Casing

Wear, Cracks

Visual, Measurement

No appreciable wear

Repair the casing

Casing to blade clearance should not exceed tolerance limits

Debris

Visual

No debris

Remove debris and clean the fan casing inside

Every inner inspections (2 years)

Inspection Date

Inspector

Results

Every coupling overhaul (4 years)

MM-M02.01

Replace or repair

Remarks

Deformation, crack and damage

Rev.003

5

Description

ANNUAL OUTAGE MAINTENANCE CHECK LIST

Forced Draft Fan Mitsubishi

4-15

Chapter 4 Preventive Maintenance

(Continued from previous page)

TABLE 4-2 No.

Major Check Item

Check Method

Moving Blade Pilot valve and Measurement Regulating sleeve Mechanism clearances

Check Reference

Action to be Taken (if beyond acceptable limit)

Remarks

Clearances are Replace the pilot valve within specified and sleeve criteria (Refer to Figure 4-1)

Recommended to replace Cylinder, Pilot valve & Sleeve every 8 years. (if have spare parts, 6 years if have not spares)

Wear of servo Measurement cylinder, sleeve

Clearance are Replace within specified criteria (Refer to Figure 4-1)

Every rotor overhaul (4 years)

Oil leakage

Visual

No oil leakage

Replace the O-rings and MV-packing

Every inner inspection (2 years)

Moving blade operation

Visual

Smooth operation

Replace defective components

Moving blade adjustment

Visual, Measurement

Adjust blades position from -40° to +14°

Adjust connecting rod length

Corresponding control drive range is 0° to 100° (0° to 90°) Every rotor overhaul (4 years)

Replacement N/A of consumable parts

N/A

Replace

Every rotor overhaul (4 years) Refer to Appendix H.

Replacement N/A of consumable parts (oil hose)

N/A

Replace

Every inner inspection (2 years) Refer to Appendix H.

Inspection Date

Inspector

Results

MM-M02.01

Rev.003

6

Description

ANNUAL OUTAGE MAINTENANCE CHECK LIST

Forced Draft Fan Mitsubishi

4-16

Chapter 4 Preventive Maintenance

(Continued from previous page

)

TABLE 4-2 No.

Description

Major Check Item Grease up

7

Linkage mechanism

Check Method

Check Reference

ANNUAL OUTAGE MAINTENANCE CHECK LIST Action to be Taken (if beyond acceptable limit)

N/A

N/A

N/A

Every year

Replacement of consumable N/A parts

N/A

Replace

Every casing overhaul (4 years) Refer to Appendix H

No appreciable Repair the silencer wear

Silencer

Wear crack

Visual

9

Control/ Lubricating Oil System

Oil condition*1

Visual

Replace oil every annual outage maintenance.

N/A

Wear or damage of oil pump 3 components*

Visual

No wear or damage

Replace defective components

Damage of control oil filters*2

Visual

No damage

Replace filter

Accumulator 2 bladder*

Visual Pressure gauge

No ageing, cracks or damage

Replace bladder

Oil cooler 3 leakage*

Visual Hydraulic test

No leak

Plug the leaking parts (packing and O-rings)

Oil cooler protecting 2 zincs*

Measurement

Their length is below 1/4 ～ 1/3 of the original length or not

Replace new one

MM-M02.01

Rev.003

8

Forced Draft Fan Mitsubishi

Remarks

Inspection Date

Inspector

Results

Drop of silencer wall leads to rotor damage. Every inner inspection (2 years) For further details, please refer to Vendors manual. *1 Interval is every 1 year. *2 Interval is every 2 years. *3 Interval Is every 4 years.

4-17

Preventive Maintenance

MM-M02.01

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Chapter 4

FIGURE 4-1 Forced Draft Fan Mitsubishi

FDF CLEARANCE DETAILS

4-18

Chapter 5

Disassembly and Reassembly

C h a p t er

5 Disassembly and Reassembly Disassembly and reassembly are the activities to be conducted when internal parts of the equipment are required to be accessed. An important part of the activities is the preparatory work. This should identify the manpower, spare parts and tools that may be required during the maintenance work. A shortfall of any of these may affect the schedule and the operational status of the plant. The major parts of the FDF are the casing, blade pitch control mechanism, bearing and the blade assembly. Except for the bearing replacement all other disassembly and reassembly of the FDF parts can be done in site. The rotor removal to a lay down area is necessary when the bearings are to be replaced as this work is possible only with shaft in vertical position. The following sections describe the details of disassembly and reassembly of various parts. The major steps associated with disassembly and assembly are as follows:

Note MHI recommends that disassembly and reassembly of FDF is carried out under MHI supervision only.

5.1

FDF Disassembly and Reassembly a)

Preparation

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Rev.003

If FDF disassembly becomes necessary, all associated equipment is to be mechanically and electrically isolated and an authorized clearance and work permit shall be in place at the location prior to the commencement of work. The following points are also to be considered when preparing for disassembly and assembly:

Forced Draft Fan Mitsubishi

•

Have all necessary drawings (assembly drawings, sectional drawings, spare part details, etc.) and documents (log sheets, field record book, etc.) ready prior to start of work.

•

Prepare the necessary handling facilities (e.g. cranes, chain blocks jacks and supports, etc.) to remove and store the various parts of the equipment.

•

Co-ordinate with the I&C Department to remove all the attached instrumentation such as vibration pick ups, thermocouples and impulse piping before starting disassembly work.

•

Move the moving blades to fully closed position before stopping the oil pumps.

5-1

Chapter 5

•

Disassembly and Reassembly

Ensure that the electrical breaker must be switched off & locked at both locations & the key must be retained by the Charge Engineer.

Special tools are listed in Appendix C.

b)

Disassembly

CAUTION When separating joints and flanges use jacking bolts and wooden mallets. Never apply force with hammers, chisels or screwdrivers. All data is to be recorded during disassembly. During disassembly, make match marks on adjoining parts for easy identification during reassembly. The disassembly procedure is described as follows:

Upper Casing Removal: Refer to Figure 2-5.

Check O₂ content inside before entering the fan compartment. O₂ content should always be >20%.

CAUTION Use the safety belt when entering inside the casing through the manhole. Take precaution against falling.

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Rev.003

When working inside of the fan, a colleague should be stationed at the entry point to provide assistance when required.

Forced Draft Fan Mitsubishi

1

Move the moving blades to a fully close position before starting disassembly of the FDF. Take care not to be close to moving blade when direction is changing.

2

Remove the insulation of the flange section of upper halves of the impeller casing (17) and rear casing (19).

3

Remove the band for casing (26) provided between rear and diffuser (upper part only) casings.

5-2

Chapter 5

Disassembly and Reassembly

4

Remove vertical joint bolts (8) between suction casing (28) and impeller casing (17) (upper part only).

5

Remove the horizontal flange bolts and nuts (9, 2&12, 1&11) connecting upper and lower half of the rear casing (19) (outer side) and impeller casing (17) (outer side).

6

Enter the discharge duct through a duct manhole.

7

Enter the diffuser inner from the manhole diffuser inner casing (29).

8

Remove the manhole cover for rear casing’s (22). Please note that the two halves of the rear inner casing do not have a bolted joint and have only metal to metal contact.

9

Enter the suction casing through the suction casing manhole (30).

10 Remove the bolt (16) connection with the impeller inner casing and intermediate shaft cover. Slide the impeller shaft cover (23) towards the motor side. 11 Remove the horizontal joint of the impeller inner casing. 12 Thus both the rear and impeller casings can be lifted together. If to be removed separately, remove the vertical joint bolts and nuts between the outer impeller casing and the rear casing also. 13 Lift the outer casing along with the connected inner casing.

CAUTION Rigging and transportation of equipment must be carried out by authorized persons. Care is to be taken while equipment weight and center of gravity is to be considered.

CAUTION Ensure that the moving blades are in the fully closed position. Removal of rear casing inner casing with moving blades in the open position leads to damage of the moving blades.

•

Special care is to be taken when lifting the casing to prevent damage to the moving blades.

•

Special care is to be taken when moving blade operates.

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Rev.003

CAUTION

Forced Draft Fan Mitsubishi

5-3

Chapter 5

Disassembly and Reassembly

Take care not to drop the part to be lifted while rigging. If the part drops on equipment the part as well as the equipment will get damaged.

Don’t stand or walk under a lifted object. If the object falls, it could lead to a fatal or a severe injury.

CAUTION While rigging, never stand or sit on the object to be lifted.

CAUTION Rise the upper casing more than 1.8m above from the moving blade to avoid contact. 14 Clean the inside of the fan casing before disassembly, to prevent the entry of any foreign material into the bearing box and the servo cylinder.

Oil Lines Removal: Refer to Figure 2-3.

CAUTION Remove the oil connections only after depressurizing the system to atmospheric pressure.

Rev.003

15 Remove the connecting pin (5 of Figure 2-8) and disconnect the pilot valve (30) of Figure 2-3 from the control drive linkage (For details of linkage assembly refer to Figure 2-8).

MM-M02.01

16 Remove the control oil inner pipings (flexible hoses) (33) from the pilot valve (30) of control oil supply, control oil return, pilot leak and oil leak line. 17 Cover the openings of oil lines immediately with cloth to prevent the entry of dust. Forced Draft Fan Mitsubishi

5-4

Chapter 5

Disassembly and Reassembly

Pilot Valve Removal: Refer to Figures 2-7 and 5-3. 18 Remove the oil cover for pilot leak (40) from the pilot valve by withdrawing machine screw (37) and washer (32). 19 Remove the bolts and washer (24 & 31) of cover (10). 20 Slowly withdraw the pilot valve (1) together with the joint (14), the bearing (6), the scroll (5) and the cover (10). 21 Provide temporary covers for the opening of the servo cylinder cover (39).

Note If pilot valve disassembly is to be done follow the steps below, pilot valve disassemble is carried out at the clean place (work shop etc.) carefully. Refer to Figures 2-7 and 5-3. The pilot valve (1) dismantling is done in the following steps: (i)

Remove the retaining rings (27) on either side of the scroll (5). Slide the pilot valve (1) with the scroll (5) and bearing (6).

(ii)

Remove the retaining ring (28) and the bearing (6) from the scroll (5).

(iii)

Remove the set screw (35) and then the scroll. Remove the spring pin (34) from the pilot valve shaft.

(iv)

Remove the cover (10) with oil seal (7) and floating ring (9) from the pilot valve (1).

(v)

Remove the retaining rings (8 & 29) on either side of cover.

(vi)

Remove the floating ring (9) and oil seal (7) and O ring (56).

(vii) Remove the bolts (25) and spring washer (33). Discard the packing (15).

Rev.003

Note :

MM-M02.01

Pilot parts shall be kept in the oil bath after disassembly.

Forced Draft Fan Mitsubishi

5-5

Chapter 5

Disassembly and Reassembly

Coupling Removal: Refer to Figure 2-5, 2-11, 5-2 and 5-9. 22 Remove the drive side coupling cover assembly (24 of Figure 2-5). 23 Fix the supporting tools with the impeller inner casing and suction casing to support the intermediate shaft as shown in Figure 5-9. 24 Install the support bar (turn buckle, washer, plate) to the rotor not to fall the rotor from the casing and be damage as shown in Figure 5.2. 25 Remove and secure the wire ( 6 of Figure 2-11). 26 Remove the reamer bolts (3 of Figure 2-11) and nuts (5 of Figure 2-11) on the rotor side of the coupling to decouple the fan from the intermediate shaft. 27 If motor removal is necessary for annual outage maintenance, remove the bolts (4 of Figure 2-11) and nuts (5 of Figure 2-11) on the motor side of the coupling to decouple motor from the intermediate shaft.

Note As per the design, the intermediate shaft cover can slide inside the suction inner casing. This arrangement will provide sufficient space for fixing the intermediate shaft centering special tool at the fan side impeller inner casing bottom half. Similarly on the motor side of the intermediate shaft sufficient space is available for fixing the centering tool on the suction inner casing bottom half after removal of coupling cover.

Rotor Assembly & Bearing Removal: Refer to Figure 2-9. 28 Disconnect and remove the lubricating oil supply pipe from the bearing box upper, and cover the openings immediately with clean clothes to prevent the entry of foreign material. 29 Drain the oil from the bearing box by removing the oil bath drain plug (27) and reinstall the plug in position. 30 Remove the temperature measuring instrument and vibration pickups from the bearing box assembly. Rev.003

31 Install eye bolts in the threaded holes provided on the bearing box and the rotor.

MM-M02.01

32 Connect the appropriate lifting gear to the lugs provided on the bearing box and the rotor wheel.

Forced Draft Fan Mitsubishi

5-6

Chapter 5

Disassembly and Reassembly

33 Remove the bolts (16 and 35), Remove the taper pins (23) in position and parallel pin (36). 34 Remove the bearing box upper half (1) and oil baffle assembly (38 & 39) upper half. 35 Adjust the slings to facilitate the vertical lifting of the combined rotor and the bearing assembly. 36 After removing the rotor and bearing assembly, cover the lower half of the bearing box by a sheet and plate.

Note To prevent the plate from moving, secure using a wire.

Note Please note that the bearing box is assembled in two halves. The removal of the bearing box lower half may be judiciously decided. If the bearing box removal is necessary, the taper pins need not be removed from its position on the lower half. Please note that the taper pins are spot welded to the eccentric bush (9) which is inserted and caulked to the base. The rotor is normally removed by removing the upper half of the bearing box as described in this section.

CAUTION Special care is to be taken when lifting the rotor assembly with blades to prevent damage to the moving blades and the bearing box.

CAUTION •

Don’t sit or stand on a rotor being removed.

•

Don’t go near a rotor being lifted.

MM-M02.01

Rev.003

37 Slowly lift up the rotor assembly with the bearing and transport it to the lay down area.

Forced Draft Fan Mitsubishi

5-7

Chapter 5

c)

Disassembly and Reassembly

Reassembly The reassembly procedure is carried out in the reverse sequence to that for disassembling. Install all parts in the same positions they were removed from, referring to the match marks and checking that the clearances are maintained as specified in Figure 4-1. All contact surfaces are to be cleaned before starting reassembly and all gaskets are to be replaced.

Note Before the installing of the rotor assembly, oil flushing is finished.

1

If disassembly of rotor has been performed, ensure that the rotor is reassembled and ready for installation as per section 5.2.

2

If disassembly of the bearing box has been performed, ensure that the bearing is reassembled and ready for installation as per section 5.3.

3

Visually inspect the fan casings to ensure that they are clean and free of foreign material before rotor installation.

4

Lift the rotor assembly slightly to ensure that the load is correctly balanced.

Take care not to drop the lifted object while rigging. If the lifting part falls, it will damage the stationary equipment.

Never stand under an object being lifted. This could cause a fatal or a severe injury.

CAUTION

Rev.003

CAUTION

MM-M02.01

Ensure that the moving blades are in the fully closed position.

Special care is to be taken when lowering the casing to prevent damage to the moving blades, and bearings.

Forced Draft Fan Mitsubishi

5-8

Chapter 5

Disassembly and Reassembly

Refer to Figures 2-9. 5

Transport the rotor assembly with the bearing, blades and servo cylinder to the fan casing.

6

Using a suitable lifting device lower the assembly slowly into the casing.

7

Take care of the proper seating of the bearing on its assigned support.

8

Install the support bar (turn buckle, washer, plate) to the rotor, not to fall the rotor from the casing as shown in Figure 5-2.

9

Remove the lifting equipment.

CAUTION Don’t sit or stand on a rotor being removed.

10 Install the upper half of bearing box and oil baffle assembly (38&39).

Note Install the bolt (35) and parallel pin (36) before installing bearing box cover to bearing box. If you don’t keep this assembling process, it leads to oil leakage.

11 Check the bearing clearances between the shaft and bearing box cover (radial & axial) with those specified in Figure 4-1. 12 Accordingly, fix the spherical keys (37) with shims (45) Figure 5-6 to the bearing keep (26), for adjusting the clearances specified in Figure 4-1. 13 Fix the bearing body stopper (3). 14 Measure and check the tolerances between the bearing box and the spherical key which is top side specified in Figure 4-1. 15 Install the bearing box taper pins (23) and parallel pin (36) in its original place on the upper half of bearing box and install bolts (16 & 35). 16 Tighten the fixing bolts (16&17) to the required torque.

Rev.003

17 Replace the consumable parts (packing etc.) and install all the bearing box oil supply lines.

MM-M02.01

18 Install the vibration monitors and the temperature measuring elements on to the bearing box. 19 Reassemble the coupling as per section 5.5 and remove the rotor support bar and coupling support. Forced Draft Fan Mitsubishi

5-9

Chapter 5

Disassembly and Reassembly

CAUTION Be careful not to place your finger between the upper and the lower casings during reassembly.

CAUTION Ensure the moving blade full close position before the installing the casing.

20 Measure the radial clearance of the impeller with the outer casings the impeller and the rear inner casing. 21 Adjust the inner casings to achieve the clearance as indicated in Figure 4-1.

CAUTION Not enough adjusting of clearance leads to contact of rotation parts and stationary parts. After completing maintenance in the oil lines of the bearing box/oil unit, do complete oil flushing using eye protection.

Note If pilot valve disassembly is done, it is reassembled as follows, pilot valve reassemble is carried out at the clean place (work shop, etc.) carefully. Refer to Figures 2-7 and 5-3. The pilot valve (1) reassembly is done in the following steps: (i) Reassemble the pilot valve with the bearing (6), scroll (5), cover (10) in the reverse order to disassembly. Note before reassembly replaced the consumable parts ( oil seal (7), floating ring (9), bearing (6), O ring and retaining ring.)

Rev.003

(ii) Install the cover (10) with oil seal (7) and floating ring (9) to the pilot valve (1)

MM-M02.01

(iii) Install the scroll (5) with the spring pin (34) and the set screw (35). Note before the installing the scroll, set the retaining ring (27) of joint side (14).

Forced Draft Fan Mitsubishi

5-10

Chapter 5

Disassembly and Reassembly

(iv) Install the retaining rings (27) on the either side of the scroll (5). (v) Install the retaining rings (28) and the bearing (6). (vi) Provide packing (15) onto the pilot valve head, install the joint (14) and secure it with spring washers (33) and bolts (25). Refer to Figure 20-7 and 5-3 22 Remove the temporary cover provided for the opening of the servo cylinder cover (39).

CAUTION Installing the pilot to the rotor should be carried out in the casing. 23 Smear lubricating oil over the pilot valve assembly and slowly insert the pilot valve assembly on the servo cylinder cover (39). 24 Tighten the bolts (24) with washers (31). 25 Install the oil cover for pilot leak (40) and secure it with spring washer (32) and screw (37). 26 Connect the control oil inner piping (Figure 2-3 (33)) to the pilot valve (1) to the control oil supply, control oil return, pilot leak, oil leak line.

Oil Lines Reassembly and Fan Normalization: Refer to Figure 2-8.

CAUTION Wear the eye protection in oil line assembly working.

Special care is to be taken with oil hose, do not bend.

Rev.003

27 Start the oil pump, operate the moving blades 28 Check for the correct lubricating oil flow.

MM-M02.01

29 Check and confirm that the system is free from any control and lubricating oil leakage.

Forced Draft Fan Mitsubishi

5-11

Chapter 5

Disassembly and Reassembly

30 Ensure the moving blade stroke from 0% to 100% (from - 40° to + 14°) as per the procedure described below. (i)

Start the oil pump and check that the oil pressure is between 1.0 and 1.5 MPa.

(ii) Locate the reference moving blade manually at the - 40° position stamped on the rotor. (iii) Move slowly the pilot valve by manual to the +14° position, and ensure the moving blade stroking smoothly. (iv) Return the pilot valve by manual to the - 40° position stamped on the rotor.

Note Ensuring of moving blade stroking may carried out before rotor installing (after rotor reassembly) by using N2 gas.

CAUTION Before the moving blade operates, check that the support bar (refer figure 5-2) is removed from the rotor. Be careful when adjusting the moving blade. It could result in the breaking of the equipment. Special care is to be taken when the moving blade operate. (Like pinching in the moving blade)

31 After ensuring the moving blade stroke, readjust that control oil pressure is between 5.39 MPa and 5.88 MPa. 32 Connect the linkage mechanism to the pilot valve joint (14). 33 Adjust and calibrate the moving blade stroke from 0% to 100% (from 40° to + 14°) as per the procedure described below. (i)

Start the oil pump and check that the oil pressure is between 1.0 5.39 MPa and 5.88 MPa..

MM-M02.01

Rev.003

(ii) Operate the control drive locally from 0% to 100% and ensure that the moving blade pitch indicator is moved form fully closed positions to fully open positions and stamped on the rotor is moved from - 40° to + 14°. Adjust the linkage mechanism if required.

Forced Draft Fan Mitsubishi

5-12

Chapter 5

Disassembly and Reassembly

(iii) Operate the control drive from the DCS from 0% to 100% to confirm that the moving blade pitch angle is in requirement with the DCS indication. Adjust the linkage mechanism if required. (iv) Record the angle of stamped on the rotor and moving blade pitch indicator on side of outer casing for every 20% DCS demand.

CAUTION Be careful when adjusting the moving blade. It could result in the breaking of the equipment. Special care is to be taken when the moving blade operate. (Like pinching in the moving blade)

Refer to Figure 2-5. 34 Install the upper halves of the impeller casing (17) and rear casings (19) by using a special tool (guide tool).

Note Check no oil leakage from the bearing box etc. before installing the upper halves of casings.

35 Measure the impeller axial clearance at the upper half of the rear and impeller inner casings. 36 Measure the radial clearance between the blades and the rear inner casing in the open position as indicated in Figure 4-1. 37 Grind the rear inner casing to achieve a clearance within the tolerance, if required.

CAUTION Don’t operate the moving blade while installing the casing.

Do not machine the moving blades to achieve the required clearance. 38 Adjust the inner casings to achieve clearance as indicated in Figure 4-1. Rev.003

CAUTION

MM-M02.01

Not enough adjusting of clearance leads to contact of rotation parts and stationary parts.

Forced Draft Fan Mitsubishi

5-13

Chapter 5

Disassembly and Reassembly

39 Install the joint bolts (1 & 11, 2 & 12, 9, 10 & 13) as required for the casings (horizontal and vertical) and tighten them after achieving the required tolerances. 40 Slide the intermediate shaft cover (23) to the rotor side and install the bolts (16) and spring washer (14). 41 Install the drive side coupling cover ass’y (24). 42 Install the band for casing (26) provided over the rear upper casing.

CAUTION Before entering through a manhole inside the casing, establish a temporary platform/grating. 43 Replace or renew the insulation around the casing joints.

CAUTION Keep a sufficient distance while fixing the upper and lower casing. If you are trapped between the casings, it could result in a fatal or a serious injury. 44 After a final inspection inside the casings, close all the manhole (22, 29 and 30 of Figure 2-5).

CAUTION Before closing the manholes/access doors to the FDF, an inspection must be carried out to ensure that no material has been left inside. If some thing remains in the fan, it could lead to serious fan damage. Before you close the manhole, check that all persons have left.

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Rev.003

45 Return the fan into service.

Forced Draft Fan Mitsubishi

5-14

Chapter-5

K

Disassembly and Reassembly

L 10400

610 1890

E TRU TH N R NO

2860

690825 600

3000

PLANT NORTH

3B

2100

700

N

700

11001000

NOTES :

11001000

600

1300

BOILER FRONT

1. THIS DRAWING SHOWS THE DISASSEMBLY PROCEDURE. PLEASE REFER TO EACH EQUIPMENT O&M FOR DETAIL.

1200

FLOOR(FL+7500)

MOTORIZED GEARED TROLLEY CHAIN BLOCK 20ton

MONORAIL

K

L 10400 5900

690 3810

2. OVERHAUL BY THIS DRAWING MAKES FAN(A) AND FAN(B) SYMMETRICAL TO BOILER CENTER.

8200

4500

min. 1380

10400

M

3040

2860

A2

1550

A3

1A BCP

FL+9400 MSL+14400

UPPER CASING 18ton

2870

J

A1

FL+3600 MSL+8600

OIL UNIT

A4

4. PARTS WEIGHT UPPER CASING ROTOR AIR HOUSING MOTOR

12400

CARRIER (SUPPLIED BY OWNER) 10000

8800

18800 15t TRUCK (SUPPLIED BY OWNER)

A

UPPER CASING 18ton

CARRIER (SUPPLIED BY OWNER)

3B

SUBMERSIBLE SCRUBBER CONVEYOR

SECTION A-A

97000-3015 : GENERAL ARRANGEMENT (SIDE VIEW)

A3 A4 D3 D4

10000

OVERHAUL OF UPPER CASING A5

MOTOR 13.2ton A1 A2

FORCED DRAFT FAN 3A

3470 1860

3810

3040

FLAME DETECTOR & FURNACE TV CAMERA COOLING AIR FAN(AC)

LOCAL PANEL

SILENCER

OIL UNIT

MOTORIZED HOIST 15ton

FLAME DETECTOR & FURNACE TV CAMERA COOLING AIR FAN(DC)

LOCAL PANEL

8800

OIL UNIT

FORCED DRAFT FAN 3B

C2

UPPER CASING 18ton A1

3470

1860

B1 B2 4500

K

B3 B4

8200

L

M

SECTION B-B 600

C3

7A

1000

C4

MONORAIL FOR MOTOR BOS FL+9400(I-450x175)

5900

10400

10000

ROTOR 5ton

AIR HOUSING 1.3ton

A2

FL+3600 MSL+8600

18800

R8000

MOTORIZED GEARED TROLLEY CHAIN BLOCK 20ton

MAX. 4420

1500

min. 1380

5A

FL+9400 MSL+14400

min 1650

3000

A

3000

FURNACE

3000

C

C1

Rev.003

2860

B R8000

8800

B

690

18800

D1 D2

BOILER

MM-M02.01

: 3.3ton : 3ton : 1.3ton : 13.2ton

5. REFERENCE DWG. No. 97000-3011 : GENERAL ARRANGEMENT 1FL(FL+0) -

5A

3B

600

C

3. OVERHAUL PROCEDURE UPPER CASING (REF. TO SECTION A-A,B-B) 1) LIFT UP THE UPPER CASING FROM THE POSITION A1 TO A2 WITH MOTORIZED GEARED TROLLEY. 2) MOVE THE UPPER CASING FROM THE POSITION A2 TO A3 AND TURN IT. 3) PUT DOWN THE UPPER CASING ON THE CARRIER FROM THE POSITION A3 TO A4 . 4) MOVE THE UPPER CASING FROM THE POSITION A5 TO TEMPORARY STORAGE AREA.

690

10t TRUCK (SUPPLIED BY 825 OWNER) 3810 3040

2860

OVERHAUL OF UPPER CASING

MONORAIL FOR ROTOR BOS FL+9400(I-450x175)

PLAN MPTD-3-0040-1

Forced Draft Fan Mitsubishi

FIGURE 5-1A

OVERHAUL PLAN FOR FDF – 1/2

5-15

Chapter-5 690

3810

3040

Disassembly and Reassembly

2860

NOTES : MOTORIZED GEARED TROLLEY CHAIN BLOCK 20ton

1800 B1

B4

MOTORIZED HOIST 15ton FL+3600 MSL+8600

3. OVERHAUL PROCEDURE ROTOR (REF. TO SECTION A-A) 1) LIFT UP THE ROTOR FROM THE POSITION POSITION B1 TO B2 WITH MOTORIZED GEARED TROLLEY. 2) MOVE THE ROTOR FROM THE POSITION B2 TO B3 . 3) PUT DOWN THE ROTOR ON THE TRUCK FROM THE POSITION B3 TO B4 .

min. 1380

MOTORIZED GEARED TROLLEY CHAIN BLOCK 20ton

A2 UPPER CASING 18ton

MAX. 4420

B2

B3

FL+9400 MSL+14400

min 1650

FL+9400 MSL+14400

2620

ROTOR 5ton

TEMPORARY RACK (SUPPLIED BY OWNER)

2. OVERHAUL BY THIS DRAWING MAKES FAN(A) AND FAN(B) SYMMETRICAL TO BOILER CENTER.

min. 1380

MONORAIL

1. THIS DRAWING SHOWS THE DISASSEMBLY PROCEDURE. PLEASE REFER TO EACH EQUIPMENT O&M FOR DETAIL.

SILENCER

A1

FL+3600 MSL+8600

AIR HOUSING (REF. TO SECTION C-C) 1) LIFT UP THE AIR HOUSING FROM THE POSITION C1 TO C2 WITH MOTORIZED HOIST. 2) MOVE THE AIR HOUSING FROM THE POSITION C2 TO C3 AND TURN IT. 3) PUT DOWN THE AIR HOUSING ON THE TRUCK FROM THE POSITION C3 TO C4 .

OIL UNIT

3470

10t TRUCK (SUPPLIED BY OWNER) 10000

8800

1860

4500

5900

18800

10400

3B

5A

8200

K

L

MOTOR (REF. TO SECTION B-B,C-C) 1) LIFT UP THE MOTOR FROM THE POSITION POSITION D1 TO D2 WITH MOTORIZED HOIST. 2) MOVE THE MOTOR FROM THE POSITION D2 TO D3 . 3) PUT DOWN THE MOTOR ON THE TRUCK FROM THE POSITION D3 TO D4 .

M

SECTION A-A

SECTION B-B

OVERHAUL OF ROTOR

OVERHAUL OF UPPER CASING

4. PARTS WEIGHT UPPER CASING ROTOR AIR HOUSING MOTOR MONORAIL MOTORIZED HOIST 15ton

MOTORIZED HOIST 15ton

SILENCER

: 3.3ton : 3ton : 1.3ton : 13.2ton

5. REFERENCE DWG. No. 97000-3011 : GENERAL ARRANGEMENT 1FL(FL+0) -

SILENCER

97000-3015 : GENERAL ARRANGEMENT (SIDE VIEW) min. 1650 MOTOR 13.2ton D3

C1

D2

1000

950

3200

C2

C3

AIR HOUSING 1.3ton

FL+9400 MSL+14400

FL+3600 MSL+8600

D1

C4

MONORAIL

3150

min. 1650

FL+9400 MSL+14400

FL+3600 MSL+8600

D4

10t TRUCK (SUPPLIED BY OWNER) 10000

15t TRUCK (SUPPLIED BY OWNER)

8800

18800

8800

18800

5A

3B

10000

5A

3B SECTION C-C

OVERHAUL OF AIR HOUSING

OVERHAUL OF MOTOR

MM-M02.01

Rev.003

SECTION C-C

MPTD-3-0040-2

Forced Draft Fan Mitsubishi

FIGURE 5-1B

OVERHAUL PLAN FOR FDF – 2/2

5-16

Chapter-5

ITEM 1 2 3

Disassembly and Reassembly

DESCRIPTION SUPPORT BAR TAPERED WASHER CENTERING TOOL ASSY

NOTE: TAKE CARE OF SETTING DIRECTION OF TAPERED WASHER

A

CL OF M/B

1

1

3 2

1

MM-M02.01

Rev.003

A

A-A

MPTD-3-1195

FIGURE 5-2 Forced Draft Fan Mitsubishi

SUPPORTING PROCEDURE OF FDF ROTOR

5-17

Chapter 5

5.2

Disassembly and Reassembly

Rotor Disassembly and Reassembly a)

Preparation If the removal of the moving blades and the hydraulic cylinder in FDF rotor becomes necessary, all associated equipment is to be mechanically and electrically isolated and an authorized work permit and valid isolation certificate shall be in place prior to the commencement of the work. The outer casings are to be removed and FDF rotor is disassembled as per section along with blades, bearing and hydraulic cylinder as per section 5.1. The following points are also to be considered while preparing for disassembly and reassembly of FDF rotor: •

Have all necessary drawings and documents (log sheets, field record book, etc.) ready prior to the start of work.

•

Prepare the necessary handling facilities (e.g. cranes, chain blocks jacks and supports, etc.) to remove and store the various parts of the equipment.

Special tools are listed in Appendix C.

CAUTION Wear safety glasses to protect your eyes during the inspection / maintenance.

CAUTION Always use the Personnel Protective Equipment (PPE) during maintenance.

Note Ensure that the rotor is set on the maintenance stand. See Figure 5-5.

b)

Disassembly

Rev.003

All data is to be recorded during the disassembly of each part. During disassembly, make match marks on the adjoining parts for reference during the reassembly. The disassembly procedure is described as follows after the disassembly of the FD fan as described under the section 5.1.

MM-M02.01

Disassembly of Moving Blades and Hydraulic Cylinder: Refer to Figures 2-6, and 5-4. 1 Forced Draft Fan Mitsubishi

Match mark the blades with their installed locations.

5-18

Chapter 5

Disassembly and Reassembly

Note Figure 5-4 shows the exploded view of the rotor consisting of blades, crank arm and sliding piece for crank arm.

2

Remove the set screw (22) and the U-nut (23) and then unscrew the nut for blade support (4) by using a special tool (spanner) for nut for M/B and place it down inside the rotor.

3

Lightly tap and remove the moving blade support bearing (36) and place it inside the rotor wheel above the nut for blade support (4).

4

Slowly pull the moving blade (1) with the Teflon ring (15).

Refer to Figures 2-7 and 5-3 5

Remove the bolts (26) and then remove the servo cylinder cover assembly (39) with pilot sleeve (2).

6

Remove the bolts (22) and washer (30), and pull up the pilot sleeve (2) with blade (4) and cover (3).

Note The pilot sleeve shall be kept in the oil bath together with pilot valve.

7

The sleeve (2) dismantling is done in the following steps: (i)

Remove the cover (3) by unscrewing the bolts (23).

(ii) Remove the blade (4) by unscrewing the screw (36). Remove the washer (32). 8

Discard the O-rings (16~21).

9

Remove the set screws (48) and then unscrew the nut for piston (43) (using special tool) from the fan shaft.

10 Remove the piston (42) with the help of special tools (draw out tool, guide bar & nut). Dismantle the piston rings (46) from the piston. Refer to Figures 2-6 & 5-4. 11 Remove the fixing bolts (20) and the side ring of actuator disk (6) from the rotor (8).

Rev.003

12 Remove the crank arm (2) as an assembly outwards from the rotor (8) after removing the retaining ring (28).

MM-M02.01

13 Remove the bush (17) from the rotor (8).

Forced Draft Fan Mitsubishi

5-19

Chapter 5

Disassembly and Reassembly

14 Remove the sliding piece with its bush inside (37) from crank arm (2) after releasing the retaining ring (29). The exceptional one number sliding piece for crank arm (with pin) (38) and its bushes (18) are also removed easily after removing the retaining ring (28). Refer to Figure 2-7 and 5-3 15 Withdraw the servo cylinder (52) axially. Unscrew the set screw (55) and then remove the bush (54) from the cylinder assembly. 16 Remove the hexagon socket head bolt (49) and then the plate for MV packing (41). Discard the packing (45). 17 Remove the parallel pin (50) and then pull out the sleeve (44). Discard the O-ring (51). (if replace the sleeve)

Note In the case of disassembly and replacement of the sleeve (44) for its wearing, apply heat to its.

c)

Reassembly The reassembly procedure is carried out in the reverse sequence to that of disassembly. Install all parts in the same positions they were removed from, referring to the match marks and checking that the clearances are maintained as specified in Figure 4-1, FDF Clearance Details. All removed gaskets and O-rings are to be discarded and replaced with new ones.

Reassembly of Moving Blades and Servo Cylinder: Refer to Figures 2-7, and 5-3. 1

Insert the O-ring (51) and then the sleeve (44) onto the fan shaft and secure it with the parallel pin (50).

2

Insert the bush (54) inside the servo cylinder (52) and fix it to the cylinder with the set screw (55)..

3

Insert the servo cylinder assembly (52) onto the sleeve (44).

4

Apply grease to the lip of the MV-packing (45), then insert the MV-packing into the slot ensuring that the lip is facing towards the piston by using special tools (guide ring, tightening plate, inset ring, guide bar & nut).

Note Rev.003

Be sure to assemble the “MV-Packing” in the direction indicated in the drawing. If assembled in reverse direction, it may cause oil

MM-M02.01

leakage. Additional details on MV-packing insertion are provided in Appendix F.

Forced Draft Fan Mitsubishi

5-20

Chapter 5

Disassembly and Reassembly

Note Use the MV-packing insert tool supplied as a special tool for the installation of MV-packing.

Note Ensure that the plate for MV packing (41) does not protrude from the servo cylinder face.

5

Install and gradually tighten the plate for MV packing (41) to the servo cylinder (52) by bolts (49).

6

Install the retaining ring (47) after final tightening of the plate for MV packing (41).

Refer to Figures 2-6 and 5-4.

Note Control match marks of moving blades and rotor. Apply specified torque on each bolt using torque wrench. Apply lubricant to the threads and seating surfaces when tightening the bolts.

CAUTION Do not use lubricants containing Molybdenum – Base such as Molycoat. If a moving blade is sticking after re-assembly, confirm the clearance and check for any crack. 7

Install bush for crank arm (17) on the rotor (8). The seam of this bush is to be located at 45º towards motor side and with respect to the direction of rotation of the rotor.

8

Install all the 13 numbers of the crank arms (2) onto the inner side holes in the rotor (8). Lock the crank arms with the retaining ring (28).

9

Install all the 13 numbers of sliding pieces for crank arm (37) and secure them in the position with the crank arm (2) by retaining ring (29). The oil less bush for sliding piece (41) is to be located on center line and 180 º opposite to the direction of rotation of rotor.

MM-M02.01

Rev.003

10 Install the crank arm (3) on the rotor (8). Lock the crank arms for blade shaft with the retaining ring (28). Install sliding piece for crank arm (with pin) (38) in the hole of the servo cylinder (35).

Forced Draft Fan Mitsubishi

5-21

Chapter 5

Disassembly and Reassembly

Note Install the moving blade such that the leading edge of the moving blade is toward the suction casing and the trailing edge toward the rear casing.

Refer to Figures 2-6 and 5-4. 11 Install the Teflon ring (15) onto the top of the holes in the outer periphery in the rotor (8). 12 Insert the moving blade with (1) through the holes in the outer periphery of rotor (8) into the involute spline hole of the crank arm (2/3).

Note Moving blade weight measurement should be carried out. Decide the blade arrangement by calculating the balancing by blade weights. Allowable unbalance is to be adjusted during a balancing procedure by additional weights.

13 While inserting the blade in the rotor (8), install the moving blade support bearing (36) along with the nut for moving blade shaft (4) through the bottom side of the outer periphery holes in the rotor (8) before locating the moving blade bottom into the spline hole of crank arm (2/3) . 14 Ensure the position of the moving blade’s shaft end on the spline hole in the crank arm (3). 15 Secure the moving blade support bearing (36) with the nut for moving blade shaft (4) by using a special tool (spanner).

CAUTION Do not machine the moving blades to achieve the required clearance.

16 While tightening the nut for moving blade shaft (4), ensure that moving blades are free to rotate by hand.

Rev.003

17 Follow the same procedure to install the remaining moving blades. Refer to Figures 2-7 and 5-3.

MM-M02.01

18 Replace the piston rings (46) on the piston, if they were removed during disassembly, then insert the piston (42) through the rotor shaft by using the special tool and locate it butting to the sleeve (44).

Forced Draft Fan Mitsubishi

5-22

Chapter 5

Disassembly and Reassembly

19 Install the nut for piston (43) and secure it by using special tool (spanner) and set screws (48). Refer to Figures 2-6 and 5-4. 20 Install the side ring of actuator disk (6) such that the hole matches the pin of the sliding piece with pin (38). 21 Tighten the bolts (20) to the specified torque as per Appendix A. Refer to Figures 2-7 and 5-3. 22 Install the sleeve (57) onto the inside surface of the servo cylinder cover (39) if removed during disassembly and secure it by set screw (58). 23 Reassemble the pilot sleeve (2) with blade (4) and the cover (3) after replacing the defective parts and the O-ring (17). 24 Install new O-rings (18 & 19) in their respective slots in the sleeve (57) and install the sleeve assembly onto the servo cylinder cover (39) and secure it with bolts and washers (22&30). 25 Install and tighten the set screw (22) and the U-nut (23) to the required torque as per Appendix A. 26 Install the servo cylinder cover (39) on to the servo cylinder (52) with bolts (26). 27 Check the 0% position of moving blade angle and cylinder position. 28 Verify that the blade root clearance is within the specified tolerance. Adjust the axial clearance of the moving blade, if necessary. 29 Ensure that the balance weights (32) are in their original locations on the rotor wheel and the screws (33) are not loose.

Note Ensure the moving blade stroke by using N2 gas etc, if possible. After ensuring the moving blade stroking, pilot valve shall be kept

MM-M02.01

Rev.003

in the oil bath till installing the rotor to the casing.

Forced Draft Fan Mitsubishi

5-23

Chapter-5

Disassembly and Reassembly

ITEM

3

PILOT VALVE PILOT SLEEVE COVER

5

SCROLL

7 8

OIL SEAL RETAINING RING FLOATING RING COVER PLUG

10

13

18 19 20

O RING O RING BOLT

24 25 27 28 29 31

RETAINING RING WASHER SPRING WASHER

33 SET SCREW 36 PARALLEL PIN CYLINDER COVER DRAIN COVER

43 45

MM-M02.01

Rev.003

54 55

FIGURE 5-3 Forced Draft Fan Mitsubishi

MB HYDRAULIC MECHANISM - EXPLODED VIEW

5-24

Chapter-5

Disassembly and Reassembly

MM-M02.01

Rev.003

1

FIGURE 5-4 Forced Draft Fan Mitsubishi

MB MECHANISM EXPLODED VIEW

5-25

Chapter 5

Disassembly and Reassembly

APPROX. 72kg

APPROX. 20kg

2 1 CL OF M/B

MAINTENANCE STAND

MM-M02.01

Rev.003

MPTD-4-1194

FIGURE 5-5 SUPPORTING PROCEDURE FOR ROTOR DISASSEMBLY & REASSEMBLY

Forced Draft Fan Mitsubishi

5-26

Chapter 5

5.3

Disassembly and Reassembly

Bearing Disassembly and Reassembly a)

Preparation If bearing disassembly becomes necessary, all associated equipment is to be mechanically and electrically isolated and an authorized work permit and valid isolation certificate is to be in place prior to the commencement of work. The outer casings are to be removed and rotor is shifted to lay down area. Please refer to section 5.1 for the details. The following points are also to be considered when preparing for disassembly and reassembly: •

Have all necessary drawings and documents (log sheets, field record book, etc.) ready prior to the start of work.

•

Prepare the necessary handling facilities (e.g. cranes, chain blocks jacks and supports, etc.) to remove and store the various parts of the equipment.

•

Remove all instrumentation such as vibration pick ups and thermometers before starting the disassembly work.

•

Prepare a suitable fixture to support the rotor assembly vertically when carrying out the disassembly and reassembly of the bearings.

Special tools are listed in Appendix C.

CAUTION Be careful not to put your finger in between the upper and the lower halves during reassembly.

CAUTION Always ensure that the wire slings, shackles, eyebolts and lifting gear are certified to the Safe Working Load (SWL).

CAUTION

MM-M02.01

Rev.003

Do not stand under a lifted object. This could lead to a fatal / or a severe injury.

Forced Draft Fan Mitsubishi

5-27

Chapter 5

b)

Disassembly and Reassembly

Disassembly The disassembly of the bearing box shall be carried out after the removal of the moving blades to prevent any damage to the blades during handling. If the servo cylinder does not require any disassembly, take due care to position the pilot valve clear off the ground while supporting the rotor assembly vertically. All data is to be recorded during the disassembly of each part. During disassembly, make match marks on the adjoining parts for reference during reassembly. The disassembly procedure is described as follows:

Note Protect the openings on the rotor with proper covers to prevent the entry of dust.

CAUTION Rigging and transportation of equipment must be carried out by authorized persons. Care is to be taken where equipment weight and center of gravity is to be considered.

CAUTION After the maintenance of oil lines of the bearing box/oil unit, ensure that oil flushing of the lines is carried out to remove any entrapped foreign matters. 1

Support the rotor assembly vertically (Refer Figure 5-7).

CAUTION Special care is to be taken to prevent the outer race of radial bearing and the bush from falling. Refer to Figure 2-6. 2

Remove the set screw (24) and nut (14).

3

Remove the driving coupling half. (Need with burner)

Rev.003

CAUTION

MM-M02.01

If remove the driving coupling half, apply with burner (propane gas)

Forced Draft Fan Mitsubishi

5-28

Chapter 5

4

Disassembly and Reassembly

Remove the sleeve for bearing (13).

Refer to Figure 2-9. 5

Match mark the plate for bearing keep (4) with the bearing keep (26) and remove the 90o elbow (22) with the connecting pipe from the plate.

6

Loosen and remove the bolts (20) and washers (21) securing the plate for bearing keep (4) with bearing body. Carefully hold the plate to avoid its fall. Also the adjusting ring bottom half (6) may fall from its position along with the plate for bearing keep. Carefully remove the adjusting ring bottom half.

7

Remove the upper half of the adjusting ring (5) from the outer race of the radial bearing by removing the stopper bolt (7).

8

Slide the plate for the bearing keep (4) down the shaft. This plate can be removed only after removal of the bearings.

9

Using a puller if required to remove the bearing keep (26) with its spherical keys (37) and shims from the bearing assembly. Remove the O-rings (10) from inside the bearing keep.

10 Remove both the thrust ball bearings (28) and the outer spacers (34) with O-rings (32). Discard the O-rings. Use puller and heat as required. 11 The inner spacers (33) for the above bearings are secured. 12 Remove the radial bearing (29) at the fan side. Use puller and heat as required. 13 The plate for bearing keep (4) can be withdrawn now from the shaft (40).

c)

Reassembly The reassembly procedure is carried out in the reverse sequence to that for disassembly. Install all parts in the same positions they were removed from, referring to the match marks and checking that the clearances are maintained as specified in Figure 4-1, Clearance Drawing for FDF. The used gaskets and O-rings are to be discarded and replaced with new ones.

Rev.003

Refer to Figures 2-9 and 5-6. Clean the bearing seating surfaces on the rotor. Minor surface corrections shall be carried out using an oilstone.

MM-M02.01

1

Forced Draft Fan Mitsubishi

5-29

Chapter 5

Disassembly and Reassembly

Note The reassembly of the bearings and the coupling hub on the rotor are to be carried out in the vertical position.

2

Insert the plate for bearing keep (4) on to the shaft (40).

3

Install the fan side radial bearing (with rollers and outer race) onto the inner race.

4

Heat the inner race of the radial bearing (29) in an oil bath to about 100°C until the inner race diameter increases by 0.1 mm.

5

Transfer the inner race of radial bearing (29) from the oil bath or oven and install it on the rotor so that the inner race abuts the step provided on the rotor.

6

A weight or pressure should be applied to the inner race to ensure it remains in contact with the step on the rotor as it cools.

7

Include the bearing inner spacer (33) and outer spacer (34)on to the radial bearing.

8

Insert the O-rings (32) on to the spacer outer.

9

Follow the heating procedure explained in Step 4.

10 Heat the thrust bearing (28) and insert it onto the rotor so that it abuts firmly onto the inner spacer and then on to the roller bearing. 11 After the ball bearing has cooled to ambient temperature, insert the next set of inner spacer (33) into the outer spacer (34). 12 Insert O-rings (32) on to the outer spacer. 13 Follow the same heating procedure to install the motor side thrust ball bearing (28). 14 Fix the upper adjusting ring (5) on to the outer race of the radial bearing (29).

Note Adjustable rings must be adjusted so as to maintain 0-0.05mm axial clearance between the bearing box, bearing box cover and adjusting ring. Bearing must be closely fitted to the bearing box.

15 Place a new O-ring (31) on the bearing keep (26). Rev.003

16 Insert the bearing keep (26) onto the set of bearings.

MM-M02.01

17 Locate the plate for bearing keep (4) in its position matching the marks provided during disassembly. Along with the plate locate the lower adjusting ring (6) also.

Forced Draft Fan Mitsubishi

5-30

Chapter-5

Disassembly and Reassembly

35

29

44

43

32

Rev.003

8

MM-M02.01

MPTD-3-0473

FIGURE 5-6 Forced Draft Fan Mitsubishi

BEARING BOX - EXPLODED VIEW

5-31

Chapter 5

Disassembly and Reassembly NUT

COUPLING

KEY

SLEEVE OF BEARING

O RING

THRUST BEARING (DE) BEARING INNER SPACER

O RING O RING

THRUST BEARING BEARING OUTER SPACER

O RING O RING RADIAL BEARING (NDE)

SET SCREW

ROTOR

MM-M02.01

Rev.003

ROTOR STAND

MPTD-4-0554

FIGURE 5-7 SUPPORTNG PROCEDURE FOR BEARING REMOVAL Forced Draft Fan Mitsubishi

5-32

Chapter 5

5.4

Disassembly and Reassembly

Moving Blade Regulating Mechanism Linkage Disassembly and Reassembly a)

Preparation Movable blade regulating mechanism linkage is not normally included in overhaul maintenance but if it should ever be necessary, the procedure is as follows. All associated equipment is to be mechanically and electrically isolated and an authorized work permit and valid isolation certificate shall be in place prior to the commencement of work. The outer casings are to be removed. Please refer to section 5.1 for the details. The following points are also to be considered while preparing for disassembly and reassembly: •

Have all necessary drawings and documents (log sheets, field record book, etc.) ready prior to the start of work.

•

Prepare the necessary handling facilities (e.g. chain blocks, slings, etc.) to remove and store the various parts of the equipment.

Special tools are listed in Appendix C.

Don’t replace parts in a running unit. Also, when replacing a new component, be careful the replacement does not fall on the impeller wheel assembly.

Prepare a temporary platform / grating to work on the defective cylinder during maintenance.

Don’t move the drive unit. Special care is to be taken when replacing the parts.

b)

Disassembly

MM-M02.01

Rev.003

All data is to be recorded during the disassembly of each part. During disassembly, make match marks on the adjoining parts for reference during the reassembly. The disassembly procedure is described as follows: Refer to Figures 2-8 and 5-8. Forced Draft Fan Mitsubishi

5-33

Chapter 5

1

Disassembly and Reassembly

Remove the split pins (19), pins (5) and nuts (11), thus disconnecting the linkage assembly both from the pilot valve end and the control drive unit. Remove the spherical bearings (6) and lever (1). While removing the pin from the lever, take care not to drop the spherical bearing (6) or the lever (1).

Note If control drive unit is to be removed from the foundation during disassembly, loosen the bolts on the stand on the control drive . For disassembly and reassembly of the control drive, please refer to the respective I&C vendor manual.

2

Remove the bolt (36), the bush (39) and the U nut and split pin (37&38) thus disconnecting the power cylinder unit from the linkage mechanism. While removing the connections on the lever (31) arrest the detective cylinder assembly so that it does not fall of and cause damage or injury to persons.

3

Remove the taper pin (21&22), U-nuts (24&25) and set screws (18&26).

4

Remove the levers (30&31) from the operating shaft (28) and remove the piece (4).

5

Remove the spring pin (23) and the pointer (29).

6

Remove the dust cover (32).

7

Remove the bolts (9), washers (12) and nuts (13); loosen set screws (34) on both ends.

8

Remove the sleeve (33). Remove the ball bearing units (7&8) secured to the operating shaft support (42).

9

Remove the taper pin (20), bolts (10) and nuts (11).

10 Remove the stand for scale plate (2) together with scale plate (3) from the operating shaft support (42). 11 Withdraw the operating shaft (28) axially from outside the rear casing (40).

c)

Reassembly

MM-M02.01

Rev.003

The reassembly procedure is carried out in the reverse sequence to that for disassembly. Install all parts in the same positions they were removed from, referring to the match marks and checking that the clearances are maintained as specified.

Forced Draft Fan Mitsubishi

5-34

Chapter 5

Disassembly and Reassembly

Refer to Figures 2-8 and 5-8. 1

Clean the operating shaft (28) and insert it through the operating shaft support (42) from outside rear casing.

2

Locate the shaft in the same position as it occupied before disassembly.

3

Locate the scale plate stand (2) on the operating shaft support (42) flange with taper pin (20).

4

Secure the scale plate stand (2) by bolts (10) and washers (15).

5

Pack the ball bearing units (7&8) at both ends with lubricating grease and insert it through the operating shaft (28).

6

Install the sleeve (33) with set screw (34) on both ends of the shaft inside the bearings.

7

Secure the ball bearing units (7&8) to the operating shaft support (42) flange with bolts (9), washers (12), (13).

8

Install the dust protective cover (32).

9

Install the scale pointer (29) and secure it to the operating shaft by the spring pin (23).

10 Insert the piece (4) then insert the lever (30) onto the operating shaft (28) from inside the rear inner casing (41). 11 Install the taper pin (21) and the U-nut (24). 12 Set the lever (30) in line with the pilot valve axis. 13 Install and tighten the set screws (18) after finalizing the lever position. 14 Install the spherical bearings (6) into the apertures provided on the lever (1), 15 Install the lever (1) and secure it with pins (5) and nuts (11) on both ends of the lever. 16 Insert the split pins (19). 17 Insert the lever (31) onto the operating shaft (28) from outside the rear housing. Rev.003

18 Install the taper pin (22) and the U-nut (25).

MM-M02.01

19 Set the lever (31) in line with the actuator lever axis. 20 Install and tighten the set screw (26) after finalizing the lever position.

Forced Draft Fan Mitsubishi

5-35

Chapter 5

Disassembly and Reassembly

21 Connect the lever (31) to the actuator linkage assembly by installing the bolt (36), nut (37) and split pin (38). 22 Ensure the direction of detective cylinder assembly (27) as shown in the Figure 5-8 before connecting the lever (31). 23 Start the control oil pump and check the blade operation from 0% to 100% by manually operating the actuator carefully. 24 Carryout any minor adjustments by altering the length of the lever (31) and/or the blade sticking detector linkage assembly to achieve the full range of blade operation. 25 Loosen the spring pin (23) and adjust the pointer (29) to match the blade position of 0% to 100%.

MM-M02.01

Rev.003

26 Tighten the spring pin after final adjustment.

Forced Draft Fan Mitsubishi

5-36

Chapter-5

Disassembly and Reassembly

ITEM

4

10

13

16 17

38

20

MM-M02.01

Rev.003

27

FIGURE 5-8 Forced Draft Fan Mitsubishi

MB REGULATING LINKAGE MECHANISM – EXPLODED VIEW 5-37

Chapter 5

5.5

Disassembly and Reassembly

Coupling Disassembly and Reassembly a)

Preparation If FDF coupling disassembly becomes necessary, all associated equipment is to be mechanically and electrically isolated and an authorized work permit and valid isolation certificate is to be in place prior to the commencement of work. The outer casings are to be removed. Please refer to section 5.1 for the details. The following points are also to be considered when preparing for disassembly and reassembly:

b)

•

Have all necessary drawings and documents (log sheets, field record book, etc.) ready prior to the start of the work.

•

Prepare the necessary handling facilities (e.g. chain blocks, slings, etc.) to remove and store the various parts of the equipment.

Disassembly All data is to be recorded during the disassembly of each part. During disassembly, make match marks on the adjoining parts for reference during reassembly. The disassembly procedure is described as follows: 1

Thoroughly clean the surrounding area and the suction casing before commencement of the work.

Refer to Figure 2-5 and proceed as follows 2

Remove the coupling cover (24) provided outside of the suction casing at the drive end.

3

Enter through the suction inner casing manhole (30) and slide the intermediate shaft cover (23) from the suction inner casing side (28).

Refer to Figure 2-11 and proceed as follows; 4

Support the intermediate shaft (7 of Figure 2-11) suitably using the supporting tools on both ends as shown in Figure 5-9.

Note As per the design, the intermediate shaft cover can slide inside the suction inner casing. This arrangement will provide sufficient space for fixing the intermediate shaft supporting special tool at the fan side. Further, the suction inner casing is supported by the suction casing. After removing the coupling Rev.003

cover the second supporting tool can be fixed on the other end of the intermediate shaft towards the motor side.

MM-M02.01

24 Remove the coupling reamer bolts (4) and nuts (5) from the coupling flange at the motor side securing the motor coupling (1) and the coupling spacer (2). Forced Draft Fan Mitsubishi

5-38

Chapter 5

Disassembly and Reassembly

Note Leave one coupling reamer bolt and nut in position (preferably at the bottom hole) to prevent the spacer from falling during removal. Loosen this bolt and nut to provide a gap for the removal of the element and the washers.

c)

6

Gently tap and rotate the spacer (2) with respect to the remaining coupling bolt.

7

Support the coupling spacer (2) suitably and remove the last coupling bolt (3) and nut (5) from the coupling between the coupling spacer (2) and the intermediate shaft (7).

8

Remove all the reamer bolts and nuts from the fan rotor coupling flange.

9

If further disassembly is required, i.e. removal of coupling hub, use the special tool to withdraw the hub from the shaft.

Reassembly

MM-M02.01

Rev.003

The reassembly procedure is carried out in the reverse sequence to that for disassembly. Install all parts in the same positions they were removed from, referring to the match marks and checking that the clearances are maintained as specified. Refer to Figures 2-11 and 4-1.

Forced Draft Fan Mitsubishi

1

Ensure that intermediate shaft (7 of Figure2-11) is supported by supporting tool.

2

Check the shaft and the internal surface of the hub and remove any scratches or blemishes on the surface.

3

Check the shaft key and the key ways to ensure that the surfaces are smooth.

4

Insert the key into the shaft key way and then into the hub key way to confirm the fit.

5

Measure the outside diameter of the shaft and the bore of the hub, and record these values.

6

Clean the shaft and the hub. Insert the key into shaft key way. Heat the hub in an oil bath to approximately 100°C and fit the hub onto the shaft.

7

Fix the reamer bolts (3&4 of Figure 2-11) on the fan side coupling. Verify run out by rotation of the fan shaft. After the verification tighten the coupling bolts and nuts to the specified torque.

8

Remove the intermediate shaft supporting tool on the fan side.

5-39

Chapter 5

9

Disassembly and Reassembly

Check the intermediate shaft level by placing a spirit level on the fan side of the intermediate shaft machined surface.

10 Check that the intermediate shaft to motor shaft coupling alignment is within the specified criteria (refer to Appendix D). 11 Make preparations for fixing the coupling reamer bolts (3 & 4 of Figure 2-11) with spacer (2 of Figure 2-11) on the motor side. Tighten the coupling bolts and nuts to the specified torque. 12 Remove the intermediate shaft supporting tool on motor sides. 13 Install the intermediate shaft cover on the fan side and the coupling cover on the motor side.

MM-M02.01

Rev.003

14 Remove the tools and tackles from inside the suction casing.

Forced Draft Fan Mitsubishi

5-40

Chapter 5

Disassembly and Reassembly

IMPELLER CASING(INNER) INTERMDIATE SHAFT COVER

B

A

SLIDE

MOTOR SIDE INTERMEDIATE SHAFT

CL OF FAN 50 20

180 (

)

3

5

5

1

4

3

4

1

2

2 B

A

9

10

7

8

B-B

6 A-A

ITEM 1 2 3 4 5 6 7 8 9 10

DESCRIPTION JOINT ADJUSTABLE BOLT PIN BEARING RETAINING RING BOLT,NUT BOLT SUPPORTING PLATE SUPPORTING PLATE SUPPORTING PLATE

MM-M02.01

Rev.003

MPTD-4-0556

FIGURE 5-9 Forced Draft Fan Mitsubishi

CENTERING TOOL ASSEMBLY FOR INTERMEDIATE SHAFT

5-41

Chapter-6

Corrective Maintenance

C h a p t er

6 Corrective Maintenance Corrective maintenance is the repair or replacement work undertaken for sudden failure of any part or component of the equipment. Though a well planned preventive maintenance program tries to minimize the probability of occurrence of sudden failure of equipment, provision for attending these unscheduled maintenance requirements is to be made. Corrective maintenance work is to be given priority depending on the seriousness of the problem faced and the impact on plant operations. The schedule for repair of any equipment should be carefully planned to keep outage time to a minimum. During such repair or replacement work, an inspection is to be carefully conducted to determine why the equipment or component has failed. Good corrective maintenance requires, not only the quick restoration of the failed equipment back into service but also demands every effort to identify and record the root cause of the failure. The inspection results can be of significant help in exploring the exact reason for the failure. The findings, along with possible rectification proposals, are to be used as a feedback to update the preventive maintenance procedures.

6.1

Prerequisites The necessary prerequisites for the corrective maintenance of the FDF are as follows:

a)

Scheduling Unlike preventive maintenance, scheduling activity only starts after failure of the equipment. Depending on the severity of the problem, the importance of the service provided by the failed equipment and availability of manpower to attend to the problem, a contingency schedule is to be prepared to solve the problem at the earliest opportunity. The schedule should clearly indicate the critical path activity and assign the priority for different parallel activities. Finally, once the schedule is agreed, strict adherence to it is to be maintained to ensure timely completion of the maintenance activity.

b)

Departmental Interface/Notification Refer to Section 4.1.2, Departmental Interface/Notification.

Isolation of Equipment Refer to Section 4.1.3, Isolation of Equipment.

d)

MM-M02.01

Rev.003

c)

Safety Precautions Refer to Section 4.1.4, Safety Precautions.

Forced Draft Fan Mitsubishi

6-1

Chapter-6

6.2

Corrective Maintenance

Preparation a)

Parts, Tools and Equipment Refer to Subsection 4.2.1 a), Parts, Tools and Equipment.

b)

Documentation Refer to Subsection 4.2.1 b), Documentation.

6.3

Troubleshooting

MM-M02.01

Rev.003

This section provides information about carrying out troubleshooting and servicing for the FDF, pertaining to mechanical maintenance staff. Tables of Faults, Possible Causes and Remedies have been provided to assist in troubleshooting by qualified users. If any new kind of problem is encountered which is not listed in the following table, contact the manufacturer for assistance.

Forced Draft Fan Mitsubishi

6-2

Chapter-6

TABLE 6-1 Fault Vibration

Corrective Maintenance

TROUBLESHOOTING – FORCED DRAFT FAN Possible Cause

Remedy

Lubricating oil supply flow/pressure low

Check oil flow in sight glass/adjust pressure control valve setting

Bearing damaged

Replace bearings

Unbalance of rotor wheel and rotor shaft due to attached foreign material or misalignment

Perform field balancing

Bearing fixing bolts loose

Tighten the fixing bolts

Coupling deformation

Replace the damaged coupling components and realign the fan and motor

Inadequate lube oil flow

Check oil flow/pressure

Excessive oil temperature

Check and adjust cooling water supply Clean the oil cooler

Ingress of debris

Check and rectify the cause for debris ingress

Suction starvation of the lube oil pump

Changeover to the standby pump. Check the suction filter

Foreign material inside the fan casing/duct

Check and remove as necessary material

Air leakage from the shaft seal or casing flanged joints or cracks developed in casing/ducting

Check for wear/cracking and repair Check and replace gasket, if necessary

Contact of rotating parts with stationary parts

Stop the fan and carry out internal inspection to check the clearances

Damage of hydraulic cylinder parts

Repair or replace the damaged parts. (Take record of difference in routine or annual outage maintenance.)

Seizure of moving blade support bearing

Replace support bearing

Misalignment of linkage/levers

Correct & adjust the alignment

Failure of oil pump

Repair or replace

Malfunction of relief valve

Readjust or replace relief valve

Strainer plugged

Clean or replace strainer

Excessive pilot valve clearance

Replace pilot valve to have proper clearance

Control/lubricating oil pressure high

Malfunction of relief valve

Readjust or replace relief valve

Control/lubricating oil leakage

O-ring failure in pilot valve

Replace O-rings

Excessive lube oil flow

Check and adjust oil flow

Excessive labyrinth seal clearance

Adjust seal clearance

Bearing temperature high

Abnormal noise

Moving blade sticking

MM-M02.01

Rev.003

Control/lubricating oil pressure low

Forced Draft Fan Mitsubishi

6-3

Chapter-7

Recommended Lubrication

C h a p t er

7 R ec om m e nde d L ubr i cat i on FD FAN RECOMMENDED LUBRICATION

MM-M02.01

Rev.003

TABLE 7-1

Forced Draft Fan Mitsubishi

7-1

Appendix A

A p p en d i x

A Torque Chart TABLE A-1 Description

TORQUE CHART

Bolt size

Quantity

Torque

Remarks

Bolt (for operating plate)

M16

16

147 N-m

-

Bolt (for cylinder cover assembly)

M16

12

147 N-m

-

Set screws and U nut (nut for M/B shaft)

M10

14

21 N-m

-

Note: Perform the following steps in sequence: Apply lubricants to the threads and seating surfaces when tightening bolts.

2

Do not use lubricant containing molybdenum when tightening bolts.

3

Tighten bolts in sequence art 120o intervals.

4

In the first stage, evenly tighten with 30% of the specified torque.

5

In the second stage, evenly tighten with 70% of the specified torque.

6

In the third stage, tighten with the specified torque.

MM-M02.01

Rev.003

1

Forced Draft Fan Mitsubishi

A-1

Appendix B

A p p en d i x

MM-M02.01

Rev.003

B Spare Parts

Forced Draft Fan Mitsubishi

B-1

Appendix B

RECOMMENDED LIST OF STRATEGIC SPARE PARTS (OFF SHORE, ONE YEAR)

MM-M02.01

Rev.003

TABLE B-1

Forced Draft Fan Mitsubishi

B-2

Appendix B

RECOMMENDED LIST OF STRATEGIC SPARE PARTS (OFF SHORE, STRATEGIC)

MM-M02.01

Rev.003

TABLE B-2

Forced Draft Fan Mitsubishi

B-3

Appendix C

A p p en d i x

MM-M02.01

Rev.003

C Special Tools

Forced Draft Fan Mitsubishi

C-1

Appendix C

TABLE C-1 Eqt. ID * (Note 1)

PJ No.

T

T

T

T

RG

RG

RG

RG

1

2

3

4

03HLB01AN1

03HLB01AN1

03HLB01AN1

03HLB01AN1

Tool ID

1-1

1-2

1-3

1-4

Special Tool Name/ Description

SUPPORTING TOOL

SUPPORTING TOOL

SUPPORTING TOOL

JOINT BAR ASSEMBLY

Name of Eqt. for which special tools used

FDF

FDF

FDF

FDF

Suppliers ID No. (Note 2)

B07100-0002001-001

B07100-0002001-002

B07100-0002001-003

B07100-0002001-004

FDF SPECIAL TOOL LIST (1 OF 7) Total Qty. Supplied for Plant

2 SET

2 SET

2 SET

10 SET

Purpose

FOR INTERMEDIATE SHAFT

FOR INTERMEDIATE SHAFT

FOR INTERMEDIATE SHAFT

FOR SUPPORTING TOOL

Ref. Instruction / Doc/Dwgs（Note # 3）

N29-10M-7093

N29-10M-7093

N29-10M-7093

N29-10M-7093

Outline View & Dimensions (Note # 4)

Weight

Remarks

11.5 kg

ASSEMBLING PARTS - ADJUSTING BOLTS: M30 (2PC) SPECIAL TOOLS SHALL BE USED UNDER MHI SUPERVISION

5.3 kg

ASSEMBLING PARTS - ADJUSTING BOLTS: M30 (1PC) SPECIAL TOOLS SHALL BE USED UNDER MHI SUPERVISION

27.8 kg

ASSEMBLING PARTS - ADJUSTING BOLTS: M30 (2PC) SPECIAL TOOLS SHALL BE USED UNDER MHI SUPERVISION

1.13 kg

ASSEMBLING PARTS - PIN : 5 PCS - BEARING: NAST 15R (5 PC) - RETAINING RING:15 (5PC) SPECIAL TOOLS SHALL BE USED UNDER MHI SUPERVISION

RG

5

03HLB01AN1

1-5

BOLT NUT M16x45

FDF

B07100-0002001-005

12 SET

FOR SUPPORTING TOOL

N29-10M-7093

0.141 kg

SPECIAL TOOLS SHALL BE USED UNDER MHI SUPERVISION

T

RG

6

03HLB01AN1

1-6

BOLT M12x55

FDF

B07100-0002001-006

8

FOR SUPPORTING TOOL

N29-10M-7093

0.068 kg

SPECIAL TOOLS SHALL BE USED UNDER MHI SUPERVISION

MM-M02.01

Rev.003

T

Forced Draft Fan Mitsubishi

C-2

Appendix C

TABLE C-1 Eqt. ID * (Note 1)

PJ No.

T

T

RG

RG

7

8

03HLB01AN1

03HLB01AN1

Tool ID

2

3-1

Special Tool Name/ Description

SPANNER

INSERT PIECE

Name of Eqt. for which special tools used

Suppliers ID No. (Note 2)

FDF

B07100-0002002-001

FDF

B07100-0002003-001

FDF SPECIAL TOOL LIST (2 OF 7) Total Qty. Supplied for Plant

Purpose

1 SET

FOR M/B FASTENING NUT

1

FOR MOVING BLADE ARM BUSH

1

FOR MOVING BLADE ARM BUSH

Ref. Instruction / Doc/Dwgs（Note # 3）

Outline View & Dimensions (Note # 4)

Weight

Remarks

1.1 kg

SPECIAL TOOLS SHALL BE USED UNDER MHI SUPERVISION

1.06 kg

SPECIAL TOOLS SHALL BE USED UNDER MHI SUPERVISION

-

0.48 kg

SPECIAL TOOLS SHALL BE USED UNDER MHI SUPERVISION

N29-10M-7093

-

RG

9

03HLB01AN1

3-2

PLATE

FDF

T

RG

10

03HLB01AN1

3-3

BOLT

FDF

B07100-0002003-003

1

FOR MOVING BLADE ARM BUSH

-

0.10 kg

SPECIAL TOOLS SHALL BE USED UNDER MHI SUPERVISION

T

RG

11

03HLB01AN1

3-4

WIRE BAND

FDF

B07100-0002003-004

2 SET

FOR MOVING BLADE ARM BUSH

-

0.05 kg

SPECIAL TOOLS SHALL BE USED UNDER MHI SUPERVISION

T

RG

12

03HLB01AN1

4-1

GUIDE RING

FDF

B07100-0002004-001

1

FOR MV PACKING

N29-10M-7093

2.7 kg

SPECIAL TOOLS SHALL BE USED UNDER MHI SUPERVISION

MM-M02.01

Rev.003

T

B07100-0002003-002

Forced Draft Fan Mitsubishi

C-3

Appendix C

TABLE C-1 Eqt. ID * (Note 1)

PJ No.

T

RG

Tool ID

Special Tool Name/ Description

Name of Eqt. for which special tools used

Suppliers ID No. (Note 2)

13

03HLB01AN1

4-2

TIGHTENING PLATE

FDF

B07100-0002004-002

FDF SPECIAL TOOL LIST (3 OF 7) Total Qty. Supplied for Plant

Purpose

1

FOR MV PACKING

Ref. Instruction / Doc/Dwgs（Note # 3）

Outline View & Dimensions (Note # 4)

Weight

Remarks

N29-10M-7093

2.4kg

SPECIAL TOOLS SHALL BE USED UNDER MHI SUPERVISION

T

RG

14

03HLB01AN1

4-3

INSERT RING

FDF

B07100-0002004-003

1

FOR MV PACKING

N29-10M-7093

3.4kg

SPECIAL TOOLS SHALL BE USED UNDER MHI SUPERVISION

T

RG

15

03HLB01AN1

4-4

GUIDE BAR & NUT M10

FDF

B07100-0002004-004

3 SET

FOR MV PACKING

N29-10M-7093

3.65 kg

SPECIAL TOOLS SHALL BE USED UNDER MHI SUPERVISION

T

RG

16

03HLB01AN1

5

SPANNER

FDF

B07100-0002005-001

1 SET

FOR NUT OF PISTON

N29-10M-7093

3.0 kg

SPECIAL TOOLS SHALL BE USED UNDER MHI SUPERVISION

T

RG

17

03HLB01AN1

6-1

DRAW OUT TOOL

FDF

B07100-0002006-001

1 SET

FOR PISTON

N29-10M-7093

3.8 kg

SPECIAL TOOLS SHALL BE USED UNDER MHI SUPERVISION

6-2

GUIDE BAR & NUTM16

FDF

B07100-0002006-002

0.26 kg

SPECIAL TOOLS SHALL BE USED UNDER MHI SUPERVISION

RG

18

03HLB01AN1

2 SET

FOR PISTON

N29-10M-7093

MM-M02.01

Rev.003

T

Forced Draft Fan Mitsubishi

C-4

Appendix C

TABLE C-1 Eqt. ID * (Note 1)

PJ No.

T

RG

Tool ID

Special Tool Name/ Description

Name of Eqt. for which special tools used

Suppliers ID No. (Note 2)

13

03HLB01AN1

4-2

TIGHTENING PLATE

FDF

B07100-0002004-002

FDF SPECIAL TOOL LIST (4 OF 7) Total Qty. Supplied for Plant

Purpose

1

FOR MV PACKING

Ref. Instruction / Doc/Dwgs（Note # 3）

Outline View & Dimensions (Note # 4)

Weight

Remarks

N29-10M-7093

2.4kg

SPECIAL TOOLS SHALL BE USED UNDER MHI SUPERVISION

T

RG

14

03HLB01AN1

4-3

INSERT RING

FDF

B07100-0002004-003

1

FOR MV PACKING

N29-10M-7093

3.4kg

SPECIAL TOOLS SHALL BE USED UNDER MHI SUPERVISION

T

RG

15

03HLB01AN1

4-4

GUIDE BAR & NUT M10

FDF

B07100-0002004-004

3 SET

FOR MV PACKING

N29-10M-7093

3.65kg

SPECIAL TOOLS SHALL BE USED UNDER MHI SUPERVISION

T

RG

16

03HLB01AN1

5

SPANNER

FDF

B07100-0002005-005

1 SET

FOR NUT OF PISTON

N29-10M-7093

3.0kg

SPECIAL TOOLS SHALL BE USED UNDER MHI SUPERVISION

T

RG

17

03HLB01AN1

6-1

DRAW OUT TOOL

FDF

B07100-0002006-001

1 SET

FOR PISTON

N29-10M-7093

3.8kg

SPECIAL TOOLS SHALL BE USED UNDER MHI SUPERVISION

6-2

GUIDE BAR & NUTM16

FDF

B07100-0002006-002

0.26kg

SPECIAL TOOLS SHALL BE USED UNDER MHI SUPERVISION

RG

18

03HLB01AN1

2 SET

FOR PISTON

N29-10M-7093

MM-M02.01

Rev.003

T

Forced Draft Fan Mitsubishi

C-5

Appendix C

TABLE C-1 Eqt. ID * (Note 1)

PJ No.

T

RG

Tool ID

Special Tool Name/ Description

FDF SPECIAL TOOL LIST (5 OF 7)

Name of Eqt. for which special tools used

Suppliers ID No. (Note 2)

1

FOR BOLT

19

03HLB01AN1

7

SOCKET WRENCH

FDF

B07100-0002007-001

Total Qty. Supplied for Plant

Purpose

Ref. Instruction / Doc/Dwgs（Note # 3）

Outline View & Dimensions (Note # 4)

Weight

Remarks

N29-10M-7093

1.74kg

SPECIAL TOOLS SHALL BE USED UNDER MHI SUPERVISION

T

RG

20

03HLB01AN1

8-1

SPECIAL EYE BOLT

FDF

B07100-0002008-001

3

FOR ROTOR

-

2.8kg

SPECIAL TOOLS SHALL BE USED UNDER MHI SUPERVISION

T

RG

21

03HLB01AN1

8-2

SPECIAL EYE BOLT

FDF

B07100-0002008-002

4

FOR ROTOR

-

1.2kg

SPECIAL TOOLS SHALL BE USED UNDER MHI SUPERVISION

T

RG

22

03HLB01AN1

9-1

GUIDE TOOL

FDF

B07100-0002009-001

4

FOR CASING

-

2.59kg

SPECIAL TOOLS SHALL BE USED UNDER MHI SUPERVISION

T

RG

23

03HLB01AN1

9-2

NUT M20

FDF

B07100-0002009-002

12

FOR CASING

-

0.059kg

SPECIAL TOOLS SHALL BE USED UNDER MHI SUPERVISION

5500 QLE-N

MM-M02.01

Rev.003

T

RG

24

03HLB01AN1

10

TORQUE WRENCH

FDF

B07100-0002010-001

1 SET

FOR BOLT

-

5.2 Kg

SPECIAL TOOLS SHALL BE USED UNDER MHI SUPERVISION

MPD-4-0579

Forced Draft Fan Mitsubishi

C-6

Appendix C

TABLE C-1 Eqt. ID * (Note 1)

PJ No.

T

RG

Tool ID

Special Tool Name/ Description

25

03HLB01AN1

11

MAINTENANCE STAND

Name of Eqt. for which special tools used

Suppliers ID No. (Note 2)

FDF SPECIAL TOOL LIST (6 OF 7) Total Qty. Supplied for Plant

Purpose

FDF

B07100-0002011-001

1 SET

FOR ROTOR ASSEMBLY

Ref. Instruction / Doc/Dwgs（Note # 3）

Outline View & Dimensions (Note # 4)

Weight

Remarks

N29-10M-7093

353kg

SPECIAL TOOLS SHALL BE USED UNDER MHI SUPERVISION

T

RG

26

03HLB01AN1

12-1

TURN BUCKLE

FDF

B07100-0002012-001

6 SET

ROTOR SUPPORT

N29-10M-7093

3.75kg

T

RG

27

03HLB01AN1

12-2

PLATE

FDF

B07100-0002012-002

6

ROTOR SUPPORT

N29-10M-7093

0.06kg

6

ROTOR SUPPORT

N29-10M-7093

0.15kg

6

ROTOR SUPPORT

-

0.48kg

T

RG

28

03HLB01AN1

12-3

WASHER

FDF

B07100-0002012-003

T

RG

29

03HLB01AN1

13-1

GAS CHARGING 3-WAY VALVE (M3-G02)

FDF

B07100-0002013-001

MHI INTERNAL REMARKS. THESE TOOLS ARE SUPPLIED WITH CASING ASSEMBLY. AFTER FDF INSTALLATION. THESE TOOLS MUST BE STORED WITH OTHER SPECIAL TOOLS IN THE TOOL BOX, TO USE THESE TOOLS IN ASSEMBLING AND DISASSEMBLING OF THE OVERHAUL. SPECIAL TOOLS SHALL BE USED UNDER MHI SUPERVISION.

SPECIAL TOOLS SHALL BE USED UNDER MHI SUPERVISION

STORE IN THE TOOL BOX FOR ACCUMULATOR. RG

30

03HLB01AN1

13-2

HOSE (H210-L02)

FDF

B07100-0002013-002

1

FOR ACCUMULATOR

-

0.64kg

SPECIAL TOOLS SHALL BE USED UNDER MHI SUPERVISION

MM-M02.01

Rev.003

T

Forced Draft Fan Mitsubishi

C-7

Appendix C

TABLE C-1 Eqt. ID * (Note 1)

PJ No.

T

RG

31

03HLB01AN1

Tool ID

13-3

Special Tool Name/ Description

PRESSURE GAUGE

Name of Eqt. for which special tools used

FDF

Suppliers ID No. (Note 2)

B07100-0002013-003

FDF SPECIAL TOOL LIST (7 OF 7) Total Qty. Supplied for Plant

1

Purpose

FOR ACCUMULATOR

Ref. Instruction / Doc/Dwgs（Note # 3）

Outline View & Dimensions (Note # 4)

Weight

Remarks

STORE IN THE TOOL BOX FOR ACCUMULATOR. -

0.18kg

SPECIAL TOOLS SHALL BE USED UNDER MHI SUPERVISION

STORE IN THE TOOL BOX FOR ACCUMULATOR.

RG

32

03HLB01AN1

13-4

ADAPTOR (AD-23)

FDF

B07100-0002013-004

1

FOR ACCUMULATOR

-

0.18kg

T

RG

33

03HLB01AN1

13-5

CAP NUT WRENCH (TWH81)

FDF

B07100-0002013-005

1

FOR ACCUMULATOR

-

1.4kg

SPECIAL TOOLS SHALL BE USED UNDER MHI SUPERVISION

MM-M02.01

Rev.003

T

Forced Draft Fan Mitsubishi

C-8

Appendix D

A p p en d i x

D Coupling Alignment The following basic alignment procedure is suitable for most motor to driven machine couplings, however, for certain types of coupling reference should be made to the manufacturers instructions. Peripheral Alignment (Using a Dial Test Indicator (DTI)). Match mark the coupling halves.

With both match marks at the top: Check DTI reading at zero.

2

Turn both shafts 90°, check DTI reading at 90°.

3

Turn both shafts a further 90°, check DTI reading at 180°.

4

Turn both shafts a further 90°, check DTI reading at 270°.

5

Turn both shafts to zero, recheck DTI reading at zero.

MM-M02.01

Rev.003

1

Forced Draft Fan Mitsubishi

D-1

Appendix D

Axial Alignment An inside micrometer or a tapered gap gauge can be used dependent upon the size of the gap between the coupling faces. This example uses an inside micrometer. Ensure both match marks at the top: 1

With shafts stationary, measure a, b, c, d.

2

Turn both shafts 180° (match marks at the bottom).

3

With shafts stationary, measure c, d, a, b.

From the readings obtained, adjustments can be made to the liners (shims) installed under the feet of the driving/driven equipment. Allowable tolerances are as follows: Flexible Couplings

Rigid Couplings

Peripheral

0.05 mm

Peripheral

0.05 mm

Axial

0.05 mm

Axial

0.05 mm

However, the Flexible Coupling supplier, Daido Precision Industries Ltd, have mentioned the following specific installation acceptance criteria:

MM-M02.01

Rev.003

Form Flex Coupling

Forced Draft Fan Mitsubishi

Maximum End Float:

±3.1 mm (0.10)

Maximum Lateral Misalignment:

31.8 mm (0.50)

D-2

Appendix E

A p p en d i x

MM-M02.01

Rev.003

E Applicable Vendor Drawings

Forced Draft Fans Mitsubishi

E-1

MM-M02.01

Rev.003

Appendix E

MPTD-3-0474

Forced Draft Fan Mitsubishi

FIGURE E-1

FORCED DRAFT FAN OUTLINE DRAWING

E-2

MM-M02.01

Rev.003

Appendix E

MPTD-3-0475

Forced Draft Fans Mitsubishi

FIGURE E-2

FORCED DRAFT FAN SECTIONAL DRAWING

E-3

MM-M02.01

Rev.003

Appendix E

MPTD-3-0477

Forced Draft Fan Mitsubishi

FIGURE E-3

FDF LUBRICANT & CONTROL OIL SYSTEM P & ID

E-4

MM-M02.01

Rev.003

Appendix E

MPTD-3-0477

Forced Draft Fan Mitsubishi

FIGURE E-4

FDF-A LUBRICANT & CONTROL OIL UNIT ASSEMBLY - 1/2

E-5

MM-M02.01

Rev.003

Appendix E

MPTD-3-1198

Forced Draft Fan Mitsubishi

FIGURE E-5

FDF-A LUBRICANT & CONTROL OIL UNIT ASSEMBLY - 2/2

E-6

MM-M02.01

Rev.003

Appendix E

MPTD-3-1199

Forced Draft Fan Mitsubishi

FIGURE E-6

FDF-B LUBRICANT & CONTROL OIL UNIT ASSEMBLY - 1/2

E-7

MM-M02.01

Rev.003

Appendix E

MPTD-3-1200

Forced Draft Fan Mitsubishi

FIGURE E-7

FDF-B LUBRICANT & CONTROL OIL UNIT ASSEMBLY - 2/2

E-8

Appendix F

A p p en d i x

MM-M02.01

Rev.003

F MV PACKING INSERTION

Forced Draft Fan Mitsubishi

F-1

Appendix F BOLT HYDRAULIC CYLINDER RETAINING RING

1 TO REPLACE THE MV PACKING, REMOVE THE BOLT, THE RETAINING RING AND THE STOPPER PLATE. REMOVE THE OLD PACKING. MV PACKING STOPPER PLATE FOR MV PACKING

2

3

INSERT THE GUIDE BARS AND THE GUIDE CYLINDER.

INSERT THE INNER ADAPTER, INSERT THE MV PACKING, INSERT THE RUBBER PACKING, LOCATE THE INSERT RING.

GUIDE BAR

GUIDE BAR

GUIDE CYLINDER

INSERT RING RUBBER PACKING

INNER ADAPTER

MV PACKING

4

5

LOCATE THE TEMPORARY STOPPER PLATE EVENLY TIGHTEN THE NUTS. GENTLY PUSH THE INSERT RING AND THE PACKING RINGS INTO THE HYDRAULIC CYLINDER.

WHEN PACKINGS ARE INSERTED REMOVE THE TEMPORARY STOPPER PLATE, THE GUIDE BAR AND THE INSERT RING, INSERT THE OUTER ADAPTER, THE ORIGINAL STOPPER PLATE, THE RETAINING RING, AND THE BOLTS, TIGHTEN THE BOLTS. BOLT

STOPPER PLATE

HYDRAULIC CYLINDER RETAINING RING

STOPPER PLATE

MM-M02.01

Rev.003

RUBBER PACKING

OUTER ADAPTER

NOTE: SPECIAL TOOLS FOR THIS PROCEDURE ITEM ARE IN SPECIAL TOOLS LIST, APPENDIX C.

RUBBER PACKING

INNER ADAPTER MV PACKING

MPTD-4-1196

FIGURE F-1 Forced Draft Fan Mitsubishi

MV PACKING INSERTION

F-2

MM-M02.01

Rev.003

Appendix F

FIGURE F-2

Forced Draft Fan Mitsubishi

MV PACKING MATERIAL & DIMENSION

F-3

Appendix G

A p p en d i x

G APPLICABLE VENDOR MANUALS Description

Manufacturer

1

Handling Manual of Lubrication Oil Unit for FD Fan

Daikin Hydraulic Engineering Co. Ltd. Japan

2

Handling Manual of Pleated Type Accumulator

Nippon Accumulator Co., Ltd. Japan

MM-M02.01

Rev.003

Item No.

Forced Draft Fan Mitsubishi

G-1

Appendix G

APPENDIX G-1

HANDLING MANUAL OF LUBRICATION OIL UNIT FOR FD FAN

Rev.003

VENDOR: DAIKIN HYDRAULIC ENGINEERING CO., LTD.

MM-M02.01

JAPAN

Forced Draft Fan Mitsubishi

G-2

Appendix G

MM-M02.01

Rev.003

1

Forced Draft Fan Mitsubishi

G-3

Appendix G

MM-M02.01

Rev.003

2

Forced Draft Fan Mitsubishi

G-4

Appendix G

MM-M02.01

Rev.003

3

Forced Draft Fan Mitsubishi

G-5

Appendix G

MM-M02.01

Rev.003

4

Forced Draft Fan Mitsubishi

G-6

Appendix G

MM-M02.01

Rev.003

5

Forced Draft Fan Mitsubishi

G-7

Appendix G

MM-M02.01

Rev.003

6

Forced Draft Fan Mitsubishi

G-8

Appendix G

MM-M02.01

Rev.003

7

Forced Draft Fan Mitsubishi

G-9

Appendix G

MM-M02.01

Rev.003

8

Forced Draft Fan Mitsubishi

G-10

Appendix G

MM-M02.01

Rev.003

9

Forced Draft Fan Mitsubishi

G-11

Appendix G

MM-M02.01

Rev.003

10

Forced Draft Fan Mitsubishi

G-12

Appendix G

MM-M02.01

Rev.003

11

Forced Draft Fan Mitsubishi

G-13

Appendix G

MM-M02.01

Rev.003

12

Forced Draft Fan Mitsubishi

G-14

Appendix G

MM-M02.01

Rev.003

13

Forced Draft Fan Mitsubishi

G-15

Appendix G

MM-M02.01

Rev.003

14

Forced Draft Fan Mitsubishi

G-16

Appendix G

MM-M02.01

Rev.003

15

Forced Draft Fan Mitsubishi

G-17

Appendix G

MM-M02.01

Rev.003

16

Forced Draft Fan Mitsubishi

G-18

Appendix G

MM-M02.01

Rev.003

17

Forced Draft Fan Mitsubishi

G-19

Appendix G

MM-M02.01

Rev.003

18

Forced Draft Fan Mitsubishi

G-20

Appendix G

MM-M02.01

Rev.003

19

Forced Draft Fan Mitsubishi

G-21

Appendix G

MM-M02.01

Rev.003

20

Forced Draft Fan Mitsubishi

G-22

Appendix G

MM-M02.01

Rev.003

21

Forced Draft Fan Mitsubishi

G-23

Appendix G

MM-M02.01

Rev.003

22

Forced Draft Fan Mitsubishi

G-24

Appendix G

MM-M02.01

Rev.003

23

Forced Draft Fan Mitsubishi

G-25

Appendix G

MM-M02.01

Rev.003

24

Forced Draft Fan Mitsubishi

G-26

Appendix G

MM-M02.01

Rev.003

25

Forced Draft Fan Mitsubishi

G-27

Appendix G

MM-M02.01

Rev.003

26

Forced Draft Fan Mitsubishi

G-28

Appendix G

MM-M02.01

Rev.003

27

Forced Draft Fan Mitsubishi

G-29

Appendix G

MM-M02.01

Rev.003

28

Forced Draft Fan Mitsubishi

G-30

Appendix G

MM-M02.01

Rev.003

29

Forced Draft Fan Mitsubishi

G-31

Appendix G

MM-M02.01

Rev.003

30

Forced Draft Fan Mitsubishi

G-32

Appendix G

MM-M02.01

Rev.003

31

Forced Draft Fan Mitsubishi

G-33

Appendix G

MM-M02.01

Rev.003

32

Forced Draft Fan Mitsubishi

G-34

Appendix G

MM-M02.01

Rev.003

33

Forced Draft Fan Mitsubishi

G-35

Appendix G

MM-M02.01

Rev.003

34

Forced Draft Fan Mitsubishi

G-36

Appendix G

MM-M02.01

Rev.003

35

Forced Draft Fan Mitsubishi

G-37

Appendix G

MM-M02.01

Rev.003

36

Forced Draft Fan Mitsubishi

G-38

Appendix G

MM-M02.01

Rev.003

37

Forced Draft Fan Mitsubishi

G-39

Appendix G

MM-M02.01

Rev.003

38

Forced Draft Fan Mitsubishi

G-40

Appendix G

MM-M02.01

Rev.003

39

Forced Draft Fan Mitsubishi

G-41

Appendix G

MM-M02.01

Rev.003

40

Forced Draft Fan Mitsubishi

G-42

Appendix G

MM-M02.01

Rev.003

41

Forced Draft Fan Mitsubishi

G-43

Appendix G

MM-M02.01

Rev.003

42

Forced Draft Fan Mitsubishi

G-44

Appendix G

MM-M02.01

Rev.003

43

Forced Draft Fan Mitsubishi

G-45

Appendix G

MM-M02.01

Rev.003

44

Forced Draft Fan Mitsubishi

G-46

Appendix G

MM-M02.01

Rev.003

45

Forced Draft Fan Mitsubishi

G-47

Appendix G

MM-M02.01

Rev.003

46

Forced Draft Fan Mitsubishi

G-48

Appendix G

MM-M02.01

Rev.003

47

Forced Draft Fan Mitsubishi

G-49

Appendix G

MM-M02.01

Rev.003

48

Forced Draft Fan Mitsubishi

G-50

Appendix G

MM-M02.01

Rev.003

49

Forced Draft Fan Mitsubishi

G-51

Appendix G

MM-M02.01

Rev.003

50

Forced Draft Fan Mitsubishi

G-52

Appendix G

MM-M02.01

Rev.003

51

Forced Draft Fan Mitsubishi

G-53

Appendix G

MM-M02.01

Rev.003

52

Forced Draft Fan Mitsubishi

G-54

Appendix G

MM-M02.01

Rev.003

53

Forced Draft Fan Mitsubishi

G-55

Appendix G

MM-M02.01

Rev.003

54

Forced Draft Fan Mitsubishi

G-56

Appendix G

MM-M02.01

Rev.003

55

Forced Draft Fan Mitsubishi

G-57

Appendix G

MM-M02.01

Rev.003

56

Forced Draft Fan Mitsubishi

G-58

Appendix G

MM-M02.01

Rev.003

57

Forced Draft Fan Mitsubishi

G-59

Appendix G

MM-M02.01

Rev.003

58

Forced Draft Fan Mitsubishi

G-60

Appendix G

MM-M02.01

Rev.003

59

Forced Draft Fan Mitsubishi

G-61

Appendix G

MM-M02.01

Rev.003

60

Forced Draft Fan Mitsubishi

G-62

Appendix G

MM-M02.01

Rev.003

61

Forced Draft Fan Mitsubishi

G-63

Appendix G

MM-M02.01

Rev.003

62

Forced Draft Fan Mitsubishi

G-64

Appendix G

MM-M02.01

Rev.003

63

Forced Draft Fan Mitsubishi

G-65

Appendix G

MM-M02.01

Rev.003

64

Forced Draft Fan Mitsubishi

G-66

Appendix G

MM-M02.01

Rev.003

65

Forced Draft Fan Mitsubishi

G-67

Appendix G

MM-M02.01

Rev.003

66

Forced Draft Fan Mitsubishi

G-68

MM-M02.01

Rev.003

Appendix G

Forced Draft Fan Mitsubishi

G-69

Appendix G

MM-M02.01

Rev.003

68

Forced Draft Fan Mitsubishi

G-70

Appendix G

MM-M02.01

Rev.003

69

Forced Draft Fan Mitsubishi

G-71

Appendix G

MM-M02.01

Rev.003

70

Forced Draft Fan Mitsubishi

G-72

Appendix G

MM-M02.01

Rev.003

71

Forced Draft Fan Mitsubishi

G-73

Appendix G

MM-M02.01

Rev.003

72

Forced Draft Fan Mitsubishi

G-74

Appendix G

MM-M02.01

Rev.003

73

Forced Draft Fan Mitsubishi

G-75

Appendix G

MM-M02.01

Rev.003

74

Forced Draft Fan Mitsubishi

G-76

Appendix G

MM-M02.01

Rev.003

75

Forced Draft Fan Mitsubishi

G-77

Appendix G

MM-M02.01

Rev.003

76

Forced Draft Fan Mitsubishi

G-78

Appendix G

MM-M02.01

Rev.003

77

Forced Draft Fan Mitsubishi

G-79

Appendix G

MM-M02.01

Rev.003

78

Forced Draft Fan Mitsubishi

G-80

Appendix G

MM-M02.01

Rev.003

79

Forced Draft Fan Mitsubishi

G-81

Appendix G

MM-M02.01

Rev.003

80

Forced Draft Fan Mitsubishi

G-82

Appendix G

MM-M02.01

Rev.003

81

Forced Draft Fan Mitsubishi

G-83

Appendix G

MM-M02.01

Rev.003

82

Forced Draft Fan Mitsubishi

G-84

Appendix G

MM-M02.01

Rev.003

83

Forced Draft Fan Mitsubishi

G-85

Appendix G

MM-M02.01

Rev.003

84

Forced Draft Fan Mitsubishi

G-86

Appendix G

MM-M02.01

Rev.003

85

Forced Draft Fan Mitsubishi

G-87

Appendix G

MM-M02.01

Rev.003

86

Forced Draft Fan Mitsubishi

G-88

Appendix G

MM-M02.01

Rev.003

87

Forced Draft Fan Mitsubishi

G-89

Appendix G

MM-M02.01

Rev.003

88

Forced Draft Fan Mitsubishi

G-90

Appendix G

MM-M02.01

Rev.003

89

Forced Draft Fan Mitsubishi

G-91

Appendix G

MM-M02.01

Rev.003

90

Forced Draft Fan Mitsubishi

G-92

Appendix G

MM-M02.01

Rev.003

91

Forced Draft Fan Mitsubishi

G-93

Appendix G

MM-M02.01

Rev.003

92

Forced Draft Fan Mitsubishi

G-94

Appendix G

APPENDIX G-2

HANDLING MANUAL OF

Rev.003

PLEATED BLADDER TYPE ACCUMULATOR

MM-M02.01

VENDOR: NIPPON ACCUMULATOR CO., LTD.

Forced Draft Fan Mitsubishi

G-95

MM-M02.01

Rev.003

Appendix G

Forced Draft Fan Mitsubishi

G-96

MM-M02.01

Rev.003

Appendix G

Forced Draft Fan Mitsubishi

G-97

MM-M02.01

Rev.003

Appendix G

Forced Draft Fan Mitsubishi

G-98

MM-M02.01

Rev.003

Appendix G

Forced Draft Fan Mitsubishi

G-99

MM-M02.01

Rev.003

Appendix G

Forced Draft Fan Mitsubishi

G-100

MM-M02.01

Rev.003

Appendix G

Forced Draft Fan Mitsubishi

G-101

MM-M02.01

Rev.003

Appendix G

Forced Draft Fan Mitsubishi

G-102

MM-M02.01

Rev.003

Appendix G

Forced Draft Fan Mitsubishi

G-103

MM-M02.01

Rev.003

Appendix G

Forced Draft Fan Mitsubishi

G-104

MM-M02.01

Rev.003

Appendix G

Forced Draft Fan Mitsubishi

G-105

MM-M02.01

Rev.003

Appendix G

Forced Draft Fan Mitsubishi

G-106

MM-M02.01

Rev.003

Appendix G

Forced Draft Fan Mitsubishi

G-107

MM-M02.01

Rev.003

Appendix G

Forced Draft Fan Mitsubishi

G-108

MM-M02.01

Rev.003

Appendix G

Forced Draft Fan Mitsubishi

G-109

MM-M02.01

Rev.003

Appendix G

Forced Draft Fan Mitsubishi

G-110

MM-M02.01

Rev.003

Appendix G

Forced Draft Fan Mitsubishi

G-111

MM-M02.01

Rev.003

Appendix G

Forced Draft Fan Mitsubishi

G-112

MM-M02.01

Rev.003

Appendix G

Forced Draft Fan Mitsubishi

G-113

MM-M02.01

Rev.003

Appendix G

Forced Draft Fan Mitsubishi

G-114

MM-M02.01

Rev.003

Appendix G

Forced Draft Fan Mitsubishi

G-115

MM-M02.01

Rev.003

Appendix G

Forced Draft Fan Mitsubishi

G-116

MM-M02.01

Rev.003

Appendix G

Forced Draft Fan Mitsubishi

G-117

MM-M02.01

Rev.003

Appendix G

Forced Draft Fan Mitsubishi

G-118

MM-M02.01

Rev.003

Appendix G

Forced Draft Fan Mitsubishi

G-119

MM-M02.01

Rev.003

Appendix G

Forced Draft Fan Mitsubishi

G-120

MM-M02.01

Rev.003

Appendix G

Forced Draft Fan Mitsubishi

G-121

MM-M02.01

Rev.003

Appendix G

Forced Draft Fan Mitsubishi

G-122

MM-M02.01

Rev.003

Appendix G

Forced Draft Fan Mitsubishi

G-123

MM-M02.01

Rev.003

Appendix G

Forced Draft Fan Mitsubishi

G-124

MM-M02.01

Rev.003

Appendix G

Forced Draft Fan Mitsubishi

G-125

MM-M02.01

Rev.003

Appendix G

Forced Draft Fan Mitsubishi

G-126

MM-M02.01

Rev.003

Appendix G

Forced Draft Fan Mitsubishi

G-127

MM-M02.01

Rev.003

Appendix G

Forced Draft Fan Mitsubishi

G-128

Appendix H

A p p en d i x

MM-M02.01

Rev.003

H PART LIST

Forced Draft Fan Mitsubishi

H-1

MM-M02.01

Rev.003

Appendix H

Forced Draft Fan Mitsubishi

H-2

MM-M02.01

Rev.003

Appendix H

Forced Draft Fan Mitsubishi

H-3

MM-M02.01

Rev.003

Appendix H

Forced Draft Fan Mitsubishi

H-4

MM-M02.01

Rev.003

Appendix H

Forced Draft Fan Mitsubishi

H-5

MM-M02.01

Rev.003

Appendix H

Forced Draft Fan Mitsubishi

H-6

MM-M02.01

Rev.003

Appendix H

Forced Draft Fan Mitsubishi

H-7

MM-M02.01

Rev.003

Appendix H

Forced Draft Fan Mitsubishi

H-8

MM-M02.01

Rev.003

Appendix H

Forced Draft Fan Mitsubishi

H-9

MM-M02.01

Rev.003

Appendix H

Forced Draft Fan Mitsubishi

H-10

MM-M02.01

Rev.003

Appendix H

Forced Draft Fan Mitsubishi

H-11

MM-M02.01

Rev.003

Appendix H

Forced Draft Fan Mitsubishi

H-12

MM-M02.01

Rev.003

Appendix H

Forced Draft Fan Mitsubishi

H-13

MM-M02.01

Rev.003

Appendix H

Forced Draft Fan Mitsubishi

H-14

MM-M02.01

Rev.003

Appendix H

Forced Draft Fan Mitsubishi

H-15

MM-M02.01

Rev.003

Appendix H

Forced Draft Fan Mitsubishi

H-16

MM-M02.01

Rev.003

Appendix H

Forced Draft Fan Mitsubishi

H-17

MM-M02.01

Rev.003

Appendix H

Forced Draft Fan Mitsubishi

H-18

MM-M02.01

Rev.003

Appendix H

Forced Draft Fan Mitsubishi

H-19

MM-M02.01

Rev.003

Appendix H

Forced Draft Fan Mitsubishi

H-20

MM-M02.01

Rev.003

Appendix H

Forced Draft Fan Mitsubishi

H-21

MM-M02.01

Rev.003

Appendix H

Forced Draft Fan Mitsubishi

H-22

MM-M02.01

Rev.003

Appendix H

Forced Draft Fan Mitsubishi

H-23

MM-M02.01

Rev.003

Appendix H

Forced Draft Fan Mitsubishi

H-24

Appendix I

A p p en d i x

MM-M02.01

Rev.003

I

Moving Blade Paint Data Sheet

Forced Draft Fan Mitsubishi

I-1

MM-M02.01

Rev.003

Appendix I

TABLE I-1 Forced Draft Fan Mitsubishi

MOVING BLADE PAINT DATA SHEET (1 of 2)

I-2

MM-M02.01

Rev.003

Appendix I

TABLE I-2 Forced Draft Fan Mitsubishi

MOVING BLADE PAINT DATA SHEET (2 of 2)

I-3