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Project Dwg. No: P101-25-1701.02-W019

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

Induced Draft Fan Maintenance Manual No. MM-M02.02 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.

Induced Draft Fan Maintenance

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···········································································································ix Personnel to whom the Manual is Directed ······················································ x Contact Address································································································xi Abbreviations ···································································································xii List of Vendor Manuals ··················································································· xiii Arrangement of the System Maintenance Manual··········································xiv

Chapter1

Safety ____________________________

1.1

Feature of Induced 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 Caution against Rotating Equipment ································· 1-11 1.4.2.2 Cautions against Electrical Equipment ······························ 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 1.3.2.5 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 Rev.003

1.4.2.8 Cautions against Lack of Oxygen ······································ 1-15 1.4.2.9 Cautions against Lifting Heavy Object ······························· 1-16

MM-M02.02

1.4.2.10Caution against Sharp Objects ········································· 1-16 1.4.2.11Cautions using Fork Lift····················································· 1-16 1.4.2.12Cautions using Crane ······················································· 1-17 Induced Draft Fan Mitsubishi

1

Contents

Chapter1

Safety (Continued from previous page…) ________ 1.4.2.13 Spare Disposal································································· 1-18

1.5

Emergency Measure······································································ 1-19 1.5.1

Evacuation on Emergency Case········································ 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 1.5.2

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 IDF ········································································· 2-2

2.4

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

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

2.4.2

Rotor Assembly···································································· 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

2.4.7

Sealing and Cooling Air System········································· 2-12

Chapter3

Specifications _____________________

Chapter4

Preventive Maintenance _____________

4.1

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

4.2

MM-M02.02

Rev.003

1.5.1.3 Evacuation from Power House ·········································· 1-20

Induced 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

2

Contents

Chapter4 4.3

Preventive Maintenance (Continued from previous page…) ________________________ Annual Outage Maintenance ························································· 4-11 4.3.1

Preparation ········································································ 4-11

4.3.2

Inspection and Maintenance ·············································· 4-12

Chapter5

Disassembly and Reassembly ________

5.1

IDF Disassembly and Reassembly ·················································· 5-1

5.2

Rotor Disassembly and Reassembly ············································· 5-17

5.3

Bearing Disassembly and Reassembly ········································· 5-33

5.4

Linkage Mechanism Disassembly and Reassembly ······················ 5-40

5.5

Coupling Disassembly and Reassembly········································ 5-45

Chapter6

Corrective Maintenance _____________

6.1

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

6.2

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

6.3

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

Chapter7

Recommended Lubrication __________

Appendixes 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 ························································ G-1

Appendix G

Applicable Vendor Manual ·················································F-1

Appendix H

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

MM-M02.02

Rev.003

Appendix A

Induced Draft Fan Mitsubishi

3

Contents

MM-M02.02

Rev.003

List of Figures Figure1-1

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

Figure 1-2

IDF Mapping for Hazardous Area······································· 1-9

Figure 2-1

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

Figure 2-2

IDF Outline Drawing··························································· 2-4

Figure 2-3

IDF Sectional View····························································· 2-5

Figure 2-4

IDF Cutaway View······························································ 2-6

Figure 2-5

IDF Casing Assembly······················································· 2-13

Figure 2-6

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

Figure 2-7

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

Figure 2-8-1

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

Figure 2-8-2

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

Figure 2-9

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

Figure 2-10

IDF Lubricant and Control Oil System P & I Diagram ······ 2-19

Figure 2-11

Form Flex Coupling·························································· 2-20

Figure 3-1

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

Figure 4-1

IDF Clearance Detail························································ 4-19

Figure 5-1A

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

Figure 5-1B

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

Figure 5-2

Moving Blade Regulating Mechanism Exploded View ····· 5-30

Figure 5-3

IDF Rotor Exploded View················································· 5-31

Figure 5-4

Removal of Rotor Disks ··················································· 5-32

Figure 5-5

Bearing Box Exploded View ··········································· 5-38

Figure 5-6

Removal of Rotor Shaft from Bearing Box ······················· 5-39

Figure 5-7

Linkage Mechanism Exploded View ································ 5-44

Figure 5-8

Supporting Tool Assembly for Form Flex Coupling ·········· 5-47

Figure E-1

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

Figure E-2

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

Figure E-3

IDF Lubricant & Control Oil System P & ID························E-4

Figure E-4

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

Figure E-5

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

Induced Draft Fan Mitsubishi

4

Contents

List of Figures (Continued from previous page…) IDF-B Lubricant & Control Oil Unit Assembly – 1/2···································································E-7

Figure E-7

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

Figure E-8

IDF Seal Air Fan Outline Drawing ······································E-9

Figure E-9

IDF Form Flex Coupling Sectional Drawing ·····················E-10

Figure F-1

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

Figure F-2

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

MM-M02.02

Rev.003

Figure E-6

Induced Draft Fan Mitsubishi

5

Contents

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

Table 3-1

Induced Draft Fan ······························································ 3-1

Table 3-2

IDF Motor ··········································································· 3-2

Table 3-3

IDF Control/Lubricating Oil Unit ········································· 3-2

Table 3-4

IDF Seal Air Fan································································· 3-3

Table 4-1

Routine Maintenance Checklist·········································· 4-8

Table 4-2

Annual Outage Maintenance Checklist ···························· 4-15

Table 6-1

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

Table 7-1

IDF Recommended Lubrication ········································· 7-1

Table A-1

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

Table B-1

Recommended List of Strategic Spare Parts (Off shore, One year) ·························································B-2

Table B-2

Recommended List of Strategic Spare Parts ·························· (Off shore, Strategic) ··························································B-3

Table H-1

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

Table H-2

Part List (2 of 8)································································· H-6

Table H-3

Part List (3 of 8)································································· H-9

Table H-4

Part List (4 of 8)······························································· H-13

Table H-5

Part List (5 of 8)······························································· H-17

Table H-6

Part List (6 of 8)······························································· H-20

Table H-7

Part List (7 of 8)······························································· H-23

Table H-8

Part List (8 of 8)······························································· H-27

MM-M02.02

Rev.003

Table 1-1

Induced Draft Fan Mitsubishi

6

Revision Record

MM-M02.02

Rev.003

Page Number

Description of Revision

Revision Issue Date

Date Revised

2-13, 2-17, 2-19

Revised in accordance with design progress.

6. Jun. 2011

6. Jun. 2011

2-14~2-16

Revise in accordance with Drawing review sheet (PE-PEHO-MHIN-D-00242)

6. Jun. 2011

6. Jun. 2011

2-17

Added drawing of blade sticking detector in accordance with drawing review sheet (PE-PEHO-MHIN-D-00242)

6. Jun. 2011

6. Jun. 2011

3-2

Corrected error

6. Jun. 2011

6. Jun. 2011

3-4

Added performance curve in accordance with drawing review sheet (PE-PEHO-MHIN-D-00242)

6. Jun. 2011

6. Jun. 2011

4-15~4-19

Revised in accordance with design progress.

6. Jun. 2011

6. Jun. 2011

Appendix-B

Revised update status.

6. Jun. 2011

6. Jun. 2011

Appendix-H

Added the part list.

6. Jun. 2011

6. Jun. 2011

2-11, 2-19, 4-9, 5-12, G-6, G-8, G-91, G-92

Changed value to meet with the commissioning results.

27. Feb. 2012

27. Feb. 2012

3-1, 4-5, 4-15, 6-3

Revise in accordance with Drawing review sheet (PE-PEHO-MHIN-D-00242)

27. Feb. 2012

27. Feb. 2012

E-4

Revised updated status.

27. Feb. 2012

27. Feb. 2012

4-10,4-20,G-17, G-143~G-151

Revised in accordance with design progress.

27. Feb. 2012

27. Feb. 2012

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

Added control oil pump specification in accordance with design progress.

27. Feb. 2012

27. Feb. 2012

G-143~G-151

Added line filter manual in accordance with design progress.

27. Feb. 2012

27. Feb. 2012

5-13

Added the comments in accordance with NCR (MBK-M-NCR-0048)

27. Feb. 2012

27. Feb. 2012

E-4

Revised updated status.

27. Feb. 2012

27. Feb. 2012

Induced Draft Fan Mitsubishi

Pages Inserted

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 only 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 IDF must be performed by the persons who have basic technical knowledge and have been trained concerning the hazard of the IDF 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 damage to the equipment or personnel have occurred by the unexpected action of operators or maintainers who do not fully understand 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 contact with MHI regarding modification or changes before the work actually commences.

MM-M02.02

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.

Induced 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 operator:

MM-M02.02

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. 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.

Induced 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.

Induced Draft Fan Mitsubishi

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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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Induced Draft Fan Mitsubishi

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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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vii



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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Induced Draft Fan Mitsubishi

viii

Copyright COPYRIGHT © 2008, 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, estoppel or otherwise, is being granted or otherwise transferred.

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Induced Draft Fan Mitsubishi

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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xi

Abbreviations Abb.

Expanded Form

Abb.

Expanded Form

American Society for Testing and Materials

DCS

Distributed Control System

BMCR

Boiler Maximum Continuous Rating

IDF

Induced Draft Fan

CCCW

Closed Circuit Cooling Water

I&C

Instrumentation and Control

CCW

Counter-Clock Wise

MB

Moving Blade

DE

Drive End

NDE

Non-Drive End

DP

Differential Pressure

NOL

Normal Oil Level

DTI

Dial Test Indicator

PPE

Personal Protective Equipment

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ASTM

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xii

List of Vendor Manuals Description

Manufacturer

1

Handling Manual of Lubrication Oil Unit for IDF

Daikin Hydraulic Engineering Co. Ltd. Japan

2

Handling Manual of Pleated Type Accumulator

Nippon Accumulator Co., Ltd. Japan

3

Instruction Manual of IDF Seal Air Fan

Azuma Sufoki Co., Ltd. Japan

4

Handling Manual of Form-Flex Coupling

Daido Precision Industries, 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 Describes health and safety issues during maintenance, disassembly and reassembly of the Induced Draft Fan.

Chapter 2 Describes the construction, purpose, and function of the Induced Draft Fan and the associated parts.

Chapter 3 Describes the Induced Draft Fan 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 Induced Draft Fan overhaul.

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

Chapter 7

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Describes the lubricants and their frequency, and quantity.

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 Induced Draft Fan Safety The Induced Draft Fan (IDF) is a double stage axial flow type and is equipped with a variable blade pitch control system. They are mainly used to evacuate the products of combustion (flue gas) from the boiler furnace by maintaining a negative pressure in the flue gas path. When a fuel is burned inside the furnace, the products of combustion contain toxic and harmful gases such as CO, NOX, CO2, SO2 etc. The flue gas containing these gases is pushed to the stack and to the atmosphere by the IDF. As a safety measure, do not make any physical contact with this flue gas. Hence, before entering into the fan for any maintenance one must ensure that the flue gas is fully evacuated and no traces remain in the fan casing and enough oxygen is available. During normal operation, even a small gas leakage in the IDF area must be noticed and stopped immediately. Touching the fan components or ducts which are already hot may cause severe burns or injuries to the power station personnel. The IDF is an important part in the boiler system. It is essential to evacuate all the remnant gases which contain some amount of unburned fuel in the boiler before startup and after shutdown. The presence of unburned fuel during a start up of the boiler can create an explosive mixture in the boiler. Thus, furnace purging by the IDF is an important logic function before performing a fuel leak test in the boiler startup. For the proper functioning of the bearings and also for the control of the blade pitch, the IDF is provided with an oil system. Any oil leak in the system is not only dangerous to the equipment but also can cause the area around the fan to be slippery leading to the fall of operating personnel. Oil leakage also can lead to a fire.

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Considering the above fact, a constant monitoring of the fan, its oil unit and seal air fan is necessary. The fan must be closely watched for any oil leakage to avoid an unsafe condition. During normal conditions, all the standard safety precautions are to be followed. During outage maintenance, proper safety procedures are to be followed by the operating personnel who will purge the system 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 Induced 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 Induced 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 Induced 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 Induced 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 Symbols 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 Induced 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 Induced 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 Hazards 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 the Induced 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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original location without delay.

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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 Induced 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 Induced

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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

Induced Draft Fan Mitsubishi

FIGURE 1-2

IDF 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 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 and the coupling.



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.

Induced Draft Fan Mitsubishi



Always, make sure 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 panels 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 clothing 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 the 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

Induced 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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Induced Draft Fan Mitsubishi

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 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.

Induced Draft Fan Mitsubishi

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-M02.02

• Avoid any impact to the unpacked parts.

Induced 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

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Rev.003

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

Induced 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-M02.02

Rev.003

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

Induced 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-M02.02

Rev.003

that there is no one missing.

Induced 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-M02.02

Rev.003

and/or system, start up the unit again.

Induced 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-M02.02

(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 the equipment due to an explosion.

Induced 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 the 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 a fundamental knowledge of the function of each equipment.



Operator can operate the equipment and the system manually at the 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 the emergency communication system operation.



Operator and Maintainer, following the Charge Engineer’s 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.

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Rev.003

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

Induced 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 ID Fans. Although this document will convey a good knowledge and direction regarding maintenance of the ID 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 and Flue Gas System MHI Dwg No. 97000-2161-1A Paiton Dwg No. P101-51-3-00-10-B049

b)

Induced Draft Fan Lubricant & Control Oil System P & ID MHI Drawing No. N29-10M-7094 Paiton Dwg. No. P101-53-3-ID-BG-W006

c)

Induced Draft Fan Particular Study MHI Drawing No.0C058-97000-2361-3A Paiton Dwg. No. P101-18-1701.02-B008

d)

Induced Draft Fan Outline Drawing MHI Dwg No. N29-10P-2390 Paiton Dwg No. P101-50-3-ID-BG-W003

e)

Induced Draft Fan Sectional Drawing MHI Dwg No. N29-10M-7095 PAITON Dwg No. P101-50-3-ID-BG-W009

f)

Overhaul Plan For Induced Draft Fan MHI Dwg No. P97000-5373 Paiton Dwg No. G101-61-3-05-00-E031

MM-M02.02

Rev.003

2.2

Induced Draft Fan Mitsubishi

2-1

Chapter 2

2.3

General

Overview of the IDF Refer to Figures 2-1 to 2-4. The Induced Draft Fans (IDF) in combination with the FDF provides a balanced draft system with the furnace under a slight negative pressure. Paiton Power Project is equipped with two IDF, each of which has the capacity to exhaust 50% of the Flue Gas from the furnace at the Boiler Maximum Continuous Rating (BMCR) condition. The fan design parameters are based on the flue gas temperature of 140ºC and a flue gas density of 0.8323 kg/m3 at the fan inlet. The IDF is a double stage axial fan with rotor moving blade pitch control. It is driven by a single speed 13.2 kV motor at a design speed of 735 rpm. Looking from the motor NDE side, the direction of rotation of the fan is CW. The two 50% BMCR capacity Induced Draft fans evacuate the products of combustion (flue gas) from the boiler furnace and maintain a slight negative pressure in the furnace. The hot flue gas from the furnace passes through boiler pressure parts transferring its energy to the water and steam. The departing flue gas from the boiler then passes through a manually operated damper and enters the Air Heater where it transfers further heat to the incoming combustion air in the Air Heater. It then passes through the Electrostatic Precipitator for particle removal before entering the Induced Draft Fan. The output from the IDF enters the FGD absorber (for SOx removal) and then to the stack or go directly to the stack through a silencer. A hydraulic mechanism regulates the blade pitch of the moving blades on the rotor which rotates at the design speed as shown in Figure 2-3. 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.

MM-M02.02

Rev.003

Two 100% capacity seal air fans supply sealing and cooling air to the fan internal compartments containing bearing box and moving blade regulating mechanism.

Induced Draft Fan Mitsubishi

2-2

General

MM-M02.02

Rev.003

Chapter 2

FIGURE 2-1 Induced Draft Fan Mitsubishi

AIR & FLUE GAS P & I D

2-3

Chapter 2

General

SEAL AIR FAN ACCUMULATOR E T RUR TH N NO N PLANT NORTH

CW

OIL UNIT

LOCAL PANEL

CL OF SUCTION

IDF 3A

DRIVE UNIT CL OF BOILER

DIFFERNTIAL PRESSURE PURGE

IDF 3B

CL OF SUCTION

MOTOR

CW

KEY PLAN SCALE 1/400

NOTE 1. THIS DRAWING SHOWS IDF 3B LAYOUT. IDF 3A LAYOUT IS MIRROR IMAGE OF THIS DRAWING.

FAN SPECIFICATION FAN TYPE

AXIAL FAN

FAN FLOW RATE

45400

IMPELLER CASING (UPPER)

mmAq(Gage)

430

mmAq(Gage)

FLUID TEMP. AT FAN INLET

140

FAN SPEED

735

FLOW

0.8323

RATED MOTOR OUTPUT

CL OF SUCTION

ROTOR

-540

FAN OUTLET STATIC PRESS.

FLUID DENSITY CL OF MOTOR

REAR CASING (UPPER)

FLOW

FAN INLET STATIC PRESS.

3

m /min/FAN

8580

o

C

rpm kg/m3 kW

ROTATION

CL OF FAN

MM-M02.02

Rev.003

MANHOLE

FL+- 0

MPTD-3-0001

Induced Draft Fan Mitsubishi

FIGURE 2-2

IDF OUTLINE DRAWING

2-4

Chapter 2

45

44

43

1

46

42

ITEM 1 2 3 4 5 6

MOTOR SIDE FLOW

61

31

34

15

23

17

3

4

60

12

40

14

2

6

26

21

22

13

9

7

5

8

19

30

ROTATION

20

33

16

29

28

27

CL OF 1ST M/B

11

SEAL AIR

SEAL AIR

37

10

24

DESCRIPTION MOVING BLADE ROTOR M/B SHAFT CRANK ARM MAIN SHAFT REGULATING SHAFT

ROTOR TIGHTEN NUT SIDE PLATE DRIVING COUPLING REGULATING DISK SIDE RING OF ACTUATOR DISK SLIDING PIECE FOR CRANK ARM NUT FOR M/B SHAFT M/B SUPPORT BEARING REGULATING DISK TIGHTEN NUT KEY KEY TORQUE LIMITER NUT KEY BUSH FOR M/B SHAFT SECURING BOLT FOR M/B BUSH FOR CRANK ARM FLEXBLE COUPLING ELEMENT BEARING BOX 1ST STAGE MAIN BEARING 2ND STAGE MAIN BEARING BEARING BOX COVER PILOT VALVE PILOT SLEEVE COVER OIL COVER FOR PILOT LEAK PISTON PISTON RING NUT FOR PISTON MV-PACKING PLATE FOR MV-PACKING SERVO CYLINDER CYLINDER COVER CONTROL OIL INNER PIPINGS SUCTION CASING IMPELLER CASING REAR CASING DIFFUSER BAND FOR CASING SEAL PLATE FOR REAR CASING

Rev.003

41

38

CL OF 2ND M/B

35

36

39

25

18

32

7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 60 61

General

MM-M02.02

MPTD-3-0023

FIGURE 2-3 Induced Draft Fan Mitsubishi

IDF SECTIONAL VIEW

2-5

Chapter 2

General

22 1

7 19

16

21

4

18

20

2

6

14 8 12 17 3

9 10

MM-M02.02

Rev.003

ITEM

DESCRIPTION

DESCRIPTION

ITEM

1

SUCTION CASING

12

DIFFUSER INNER CASING MANHOLE

2

IMPELLER CASING (UPPER)

13

SEAL PLATE ASS'Y FOR REAR CASING

3

IMPELLER CASING (LOWER)

14

FLEXIBLE COUPLING

4

REAR CASING (UPPER)

15

COUPLING COVER ASS'Y

5

REAR CASING (LOWER)

16

LADDER

6

DIFFUSER

17

1ST ROTOR DISK

7

SEAL BAND ASS'Y

18

2ND ROTOR DISK

8

SUCTION INNER CASING

19

MOVING BLADE

9

SUCTION CASING MANHOLE

20

BEARING BOX

10

SUCTION INNER CASING MANHOLE

21

HYDRAULIC MECHANISM ASS`Y

11

MANHOLE COVER FOR REAR CASING

22

MOTOR

MPTD-3-0027

FIGURE 2-4 Induced Draft Fan Mitsubishi

IDF CUTAWAY VIEW

2-6

Chapter 2

2.4

General

Components Each IDF consists of the following major components: •

Casing



Rotor assembly



Moving blade regulating mechanism



Main bearing assembly



Control/lubricating oil system



Coupling



Sealing and cooling air system

2.4.1

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

suction casing



impeller casing



rear casing



diffuser casing

The fan casing sections are all bolted and seal welded (except overhaul section) to each other. The suction casing is connected to the suction duct through an expansion joint. A blind drain pipe is provided for 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 of the fan casing. The suction casing shape changes from rectangular to circular, in the direction of the flow. The impeller casing, rear casing and diffuser 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 suction casing and the impeller casing.

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Rev.003

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

2-7

Chapter 2

General

Flue gas flows down into the suction casing. 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 is along the circumference of the tip circle of the moving blades is machined surface. Openings provided on the impeller casing facilitate the routing of seal cooling air and the fan bearing lubricating oil lines. The inner casing (not bolted), installed within the impeller casing protects the bearing box from damage. The inner surface of the impeller inner casing is insulated to protect the bearing box and bearings from overheating. The upper half of the impeller casing out side is bolted to the lower half for easy removal during maintenance.

» Rear casing The rear casing is of a 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 and the components of the moving blade regulating mechanism.

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Rev.003

The rear casing facilitates the routing of the moving blades operating shaft. The seal cooling air, control oil supply and return lines to the moving blade regulating mechanism are also routed through the rear casing.

Induced 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 the inspection and maintenance of the moving blade regulating mechanism. The inner surface of the rear inner casing is insulated to protect the moving blade regulating mechanism from overheating.

» Diffuser 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 is provided on the diffuser inner casing for the entry of personnel from the discharge duct and to carryout inspection and maintenance of the moving blade regulating mechanism.

2.4.2 Rotor Assembly Refer to Figures 2-3 and 2-6. The rotor assembly consists of a rotor shaft and a rotor. The rotor is a forged component and is keyed to the rotor shaft. The rotor assembly is supported on the main shaft at two points 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 driving coupling is keyed onto the shaft at the drive end of the regulating shaft with torque limiter and bolted to the rotor. The rotor is comprised of the moving blades, the moving blade shafts and the moving blade regulating mechanism. The moving blade shafts are supported by the moving blade support bearings and nuts. The moving blade support bearings are of the sealed type. An annular seals are provided on the side plate on the DE side of the rear inner casing. These arrangements reduce seal air leakage to the flue gas and prevent dust entry to the bearings and the servo cylinder.

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Rev.003

The piston applied as blade pitch regulating servo cylinder is located on the rotor boss. The piston is fixed to the regulating shaft and the servo cylinder is fixed to the rotor. The piston moves axially over the servo cylinder while both parts are rotating. The axial movement of the piston is converted into rotary movement of the blades by a crank arm connecting the moving blade shaft.

Induced Draft Fan Mitsubishi

2-9

Chapter 2

General

The moving blades, made of cast steel, have a good wear and corrosion resistance properties. The moving blades have a laminar flow blade profile, high efficiency and a good performance characteristic. The moving blades are bolted onto the moving blade shafts. Provision is made on the side plates of the rotor to fix balance weights required for the dynamic balancing of the unit. The torque limiter provided on the fan shaft limits the torque transmitted to the bushes in the rotating blade shafts, thus reducing the wear and tear of the bushes at fan startup.

2.4.3 Moving Blade Regulating Mechanism Refer to Figures 2-7 and 2-8. The moving blade regulating mechanism regulates the blade pitch while the fan operates at the rated speed. The moving blade regulating mechanism consists of an axially moving piston mounted on to the regulating shaft NDE, an axially fixed servo cylinder and the pilot valve. The piston is fixed on to the regulating shaft NDE collar and locked with a nut. The servo cylinder and the piston rotate at the same speed as the rotor and piston alone is free to move axially. A pilot valve can move axially only and is located inside a sleeve secured to the inside the regulating shaft on the NDE side. This pilot valve moves in and out to allow the flow of control oil as necessary to operate the moving blades. Control oil inner pipings (flexible hoses) on the pilot valve head enable the flow of supply and return, control oils and leakage oil through the oil cover for pilot leak. 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 link rotates the moving blades through an angle of –40° to +16.3°. A moving blade sticking detector is provided on the linkage between the control drive outside of the fan casing to detect any excessive load for operation of the blades.

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Rev.003

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

Induced 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 is simply supported at two locations within the bearing box. The bearing box contains an anti friction cylindrical roller bearing and two ball bearings at the non drive end and an antifriction cylindrical roller bearing at the drive end. The cylindrical roller bearings absorb the radial load and the ball bearings absorbs the thrust load generated by the fan work. End covers fitted on either side of the bearing box are provided with 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 bottom of 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 Figure 2-10. The control/lubricating oil system consists of: •

one 1400 liter capacity oil tank



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



control oil pump suction strainers



control oil pump discharge strainers



lubricating oil duplex strainers



lubricating oil cooler



one return oil strainer



an accumulator (control oil)

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Rev.003

The oil pumps mounted on the top of the tank draw oil from the tank through dedicated suction strainers. The oil is then filtered by two 100% capacity oil strainers and supplied as control oil at about 7.5~7.85MPa for the blade regulating mechanism. An oil accumulator (pre-charge N2 pressure at 1.4 MPa) installed in the control oil supply line to supply lubricating oil to pilot valve in tripping of both of control oil pump.

Induced Draft Fan Mitsubishi

2-11

Chapter 2

General

Pressure reducing valves reduce the pressure of the control oil to about 0.16 to 0.19 MPa for lubricating oil supply to the fan bearings. The return control oil from the blade regulating mechanism is also directed to the lubricating oil supply line. Oil cooler receives cooling water from the CCCW System to cool the lubricating oil before admitting to the bearing boxes. The oil tank is provided with a return oil filter to collect debris in the return oil. For further details please refer to the Vendor manual, Appendix F.

2.4.6 Coupling Refer to Figure 2-11. The fan rotor is coupled to the drive motor with a flexible coupling. The flexible coupling accommodates any minor angular, parallel and axial misalignment due to thermal expansion. The coupling consists of two hubs, a spacer, two flexible elements, an end plate, overload washers, bushes, reamer bolts and nuts. Each flexible element is an assembly of thin metal laminations.

2.4.7 Sealing and Cooling Air System Refer to Figures 2-3. Seal air is supplied to the impeller and rear inner casings of the IDF to prevent the ingress of hot flue gas into the blade regulating mechanism, fan bearing box. The seal air together with thermal insulation reduces thermal radiation from the flue gas to the inner casings and prevents the components from overheating damage and wear from dust of flue gas.

MM-M02.02

Rev.003

One of the two 100% capacity seal air fans draw atmospheric air through dedicated suction strainers and supply seal air separately to the inner impeller casing and the rear casing. Seals provided inside the inner casings prevent excessive seal air leakage along the rotor and the drive shaft.

Induced Draft Fan Mitsubishi

2-12

Chapter 2

82 83 62 73

DESCRIPTION

ITEM

84

71

61 72

General

24

FLEXIBLE COUPLING

50

SUCTION CASING

51U IMPELLER CASING (UPPER)

67 75 84

66 76

51L

IMPELLER CASING (LOWER)

52U REAR CASING (UPPER)

84 65 76

52L

REAR CASING (LOWER)

53

DIFFUSER

54

BAND FOR CASING

55IU SUCTION INNER CASING (UPPER) 55IL SUCTION INNER CASING (LOWER)

FLOW

A-A

68

60

52U

60

51U

55IU

54

A

60

68

A 51IU

80

64 76 57

24

81

MOTOR SIDE

63 59

CL OF 1'st M/B

C L OF 2'nd M/B

52IU

CL OF SUCTION

53

79

58

77 52IL

51IL

78

67

56

SEAL PLATE FOR REAR CASING

57

REAR CASING MANHOLE COVER

58

COUPLING COVER ASS'Y

59

COVER

60

LADDER

61

THREAD END TAPER PINS 30x110

62

THREAD END TAPER PINS 40x130

63

BOLT M10x16

64

BOLT M12x25

65

BOLT,NUT M12x25

66

BOLT,NUT M12x65

67

BOLT,NUT M16x50

68

BOLT,NUT M16x45

69

BOLT,NUT M20x50

70

BOLT,NUT M20x55

71

BOLT,NUT M20x75

72

NUT M30

73

NUT M24

74

SPRING WASHER M20

75

SPRING WASHER M16

76

SPRING WASHER M12

77

SUCTION CASING MANHOLE

78

SUCTION INNER CASING MANHOLE

79

DIFFUSER INNER CASING MANHOLE

80

HUB (FAN SIDE)

81

COUPLING PROTECTION CYLINDER

82

BOLT,NUT M20x70

83

SPECIAL NUT

84

GASKET

NOTE

50

2. REPLACE PARTS SHALL BE PURCHASED FROM MHI. 3. THE CASE OF PURCHASE THE PARTS, PLEASE INFORM THE PARTS ORDER No. AND NAME IN APPENDIX "H".

MM-M02.02

Rev.003

GL+0 -

MPTD-3-0061

1. LOWER CASING (MARKED )TO BE SEAL WELDED IN THE SITE. UPPER CASING (IMPELLER CASING AND REAR CASING) NOT TO BE SEAL WELDED.

69

56

52L

70

51L

55IL

71

70 74 FIGURE 2-5

Induced Draft Fan Mitsubishi

IDF CASING ASSEMBLY 2-13

Chapter 2

ITEM

ROTATION

MOVING BLADE

2

MAIN SHAFT

3

REGULATING SHAFT

4

DRIVING COUPLING

5

1ST ROTOR

6

2ND ROTOR

7

M/B SHAFT

8

CRANK ARM

9

7

1ST REGULATING DISK

10

2ND REGULATING DISK

11

6

56

SIDE RING OF ACTUATOR DISK

12

SIDE PLATE

13

A

NUT FOR M/B SHAFT

14

ROTOR TIGHTEN NUT

15

43 36

ROTOR TIGHTEN NUT

16

REGULATING DISK TIGHTEN NUT

17

37 38

REGULATING DISK TIGHTEN NUT

18

NUT

19

KEY

11

20

KEY

21

41 28

21

KEY

31

22

KEY

23

BUSH FOR M/B SHAFT

24

BUSH FOR CRANK ARM

25

BUSH FOR REGULATING SHAFT

26

RETAINING RING

27

COVER FOR M/B SUPPORT BEARING

28

STOPPER PLATE FOR BUSH

29

BOLT M30x80

30

BOLT M30x142

31

BOLT M30x105

32

BOLT M32

33

BOLT M30x70

34

WASHER

35

WASHER

36

BALANCING WEIGHT

37

U NUT

38

SET SCREW

M10x45

39

REAMER BOLT

M42

40

NUT

M42

41

MACHINE SCREW M6x14

17

42

SET SCREW

M8x12

43

SET SCREW

M10x40

33

44

SET SCREW

M12x16

45

RETAINING RING

12

46

SLEEVE FOR BRG. KEEP

47

SLEEVE FOR BRG. KEEP

48

O RING P315

49

HUB (FAN SIDE)

50

SPACER

51

SERVO CYLINDER

52

SIDE PLATE

53

SLIDING PIECE FOR CRANK ARM

54

TORQUE LIMITER

55

FRICTION DISK

56

M/B SUPPORT BEARING

57

FLEXIBLE COUPLING

58

1ST STAGE MAIN BEARING

59

2ND STAGE MAIN BEARING

23

13

8 19

48

19

58

26

45

9 CLOSE

2

OPEN

ROTATION

ROT ATIO N

29

53

59

CLOSE

No.1 M/B

5

A

50 BEARING BOX ASS'Y

10

OPEN

27

24

30 51

FLOW

20

FLOW

32

4 22 57 49

3

A

A 42

A-A

18 34 55

35 25

44 CL OF 1ST BRG.

CL OF BRG.

CL OF BRG.

46

CLOSED

OPEN

STROKE RANGE

-40 DEG.

+20 DEG.

RATED STROKE

-40 DEG. ( 0% )

+16.3 DEG. ( 100% )

15

54

39 40

NOTES 1. REPLACE PARTS SHALL BE PURCHASED FROM MHI. 2. THE CASE OF PURCHASE THE PARTS, PLEASE INFORM THE PARTS ORDER No. AND NAME IN APPENDIX "H".

M10

MPDT-3-0062

MM-M02.02

Rev.003

CL OF 2ND M/B

52

CL OF 2ND BRG.

14 47

CL OF 1ST M/B

16

DESCRIPTION

1

MOTOR SIDE

1

General

FIGURE 2-6 Induced Draft Fan Mitsubishi

ROTOR ASSEMBLY 2-14

Chapter 2

12 19

46

1

5

ITEM

2 41

13

18 32 24

11

43

45 D

31 25

43

4 E

OPEN

84.2

21

A

42 30 CLOSE

20

C

41

A-A

B

40.8

ROTATION

8 9 3

ROTATION

E

A 7

B

F

C

44

37

3 38

27

46 PILOT LEAK

17

47

B-B

40

7

28 49 48

36

OIL FLOW LEGEND

15

OIL SUPPLY OIL RETURN OIL LEAK PILOT MOVES IN PILOT MOVES OUT

1

2

29

C-C

10

6

1 2

14

1

34

2

14

23

36

DET. D

34 26 30

ROTATION

General

DESCRIPTION

1

SERVO CYLINDER

2

CYLINDER COVER

3

PILOT VALVE

4

PILOT SLEEVE

5

PISTON

6

NUT FOR PISTON

7

COVER

8

JOINT

9

PACKING

10

PLATE FOR MV PACKING

11

PLATE FOR MV PACKING

12

BOLT M12x126.5

13

PISTON RING

14

SCROLL

15

FLOATING RING

16

BLADE

17

MV PACKING

18

MV PACKING

19

WASHER

20

O RING

21

O RING

22

BEARING

23

OIL SEAL

24

BOLT M8x16

25

BOLT M10x25

26

MACHINE SCREW M6x14

27

SCREW M8x12

28

STRAIGHT PIN

29

STRAIGHT PIN

30

SPRING WASHER M6

31

SPRING WASHER M10

32

WASHER M8

33

SPRING PIN

34

RETAINING RING 60

35

RETAINING RING 80

36

RETAINING RING 80

37

RETAINING RING 18

38

O RING G100

39

O RING G105

40

O RING G15

41

PLUG

42

SCREW M6x16

43

OIL COVER FOR PAILOT LEAK

44

BUSH

45

BUSH

NTP 3/8

46

SCREW M8x8

47

BOLT M10x25

48

BOLT M10x25

49

RETAINING RING 18

14 33

3 16

39

DET. F

E-E

1. REPLACE PARTS SHALL BE PURCHASED FROM MHI. 2. THE CASE OF PURCHASE THE PARTS, PLEASE INFORM THE PARTS ORDER No. AND NAME IN APPENDIX "H".

MPTD-3-0063

MM-M02.02

Rev.003

35 22

NOTES

FIGURE 2-7 Induced Draft Fan Mitsubishi

MOVING BLADE REGULATING MECHANISM ASSEMBLY 2-15

Chapter 2 MOTOR SIDE

6

20

19

5

12

12

20

19

5

6

A

A

CL OF 2nd M/B

B

19

1

CLOSE SIDE

OPEN SIDE

32 4 9

FLOW

13 14

32 22

8

26

30

18

DET. B C

A-A

C

30

D

OPEN SIDE

CLOSE SIDE

33

21

23

11 16

15 17

2

33

7 14 13

D

3

9 DUST PROTECT COVER

29

CONTROL DRIVE TYPE:DU-35SHL O LL FU

o

3o

No.A FAN

No.B FAN

LL FU E OS CL

MM-M02.02

Rev.003

34

35

KEY PLAN VIEW FROM MOTOR SIDE MARK B IS OPPOSITE TO MARK A WITH REGARD TO LOCATIONS OF LINK MECHANISM

MPTD-3-0064

C-C

28

31

N PE

64.

10 25

27

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20

LEVER STAND FOR SCALE PLATE SCALE PLATE PIECE PIN SPHERICAL BEARING BALL BEARING UNIT BALL BEARING UNIT BOLT M12x45 BOLT M16x35 SOCKET HEAD BOLT M8x25 NUT M8 WASHER M12 SPRING WASHER M12 SPRING WASHER M4 WASHER M8 SCREW M4x6 SET SCREW M8x20 SET SCREW M5x6 SPLIT PIN TAPER PIN THREAD END TAPER PIN THREAD END TAPER PIN SPRING PIN WASHER M16 U-NUT M8

21 22 23 24 25 26 27 28 29 30 31 32 33 34 35

U-NUT M6 SET SCREW M8x14 BLADE STICKING DETECTOR OPERATING SHAFT POINTER LEVER LEVER STAND FOR DRIVE UNIT HAWK ANCHOR BOLT M16

NOTES 1. THIS DRAWING SHOWS MOVING BLADES ARE IN NEUTRAL POSITION.(MOVING BLADE ANGLE 0 ) ASSEMBLY WORK AT FULL CLOSE POSITION. 2. OPERATING DIRECTION OF CONTROL DRIVE LEVER (VIEW FROM LEVER SIDE) A = CLOCKWISE (CLOSE > OPEN) B = COUNTER- CLOCKWISE (CLOSE > OPEN) 3. PUNCHING THE SET SCREW (*1) AND TAPER PIN (*1) AT 2 PLACES EACH ON CIRCUMFERENCE AFTER ASSEMBLING. (STRICT OBSERVANCE) 4. APPLY GREASE TO FRICTIONAL SURFACE AND SPHERICAL BRG. AT ASSEMBLING. 5. REPLACE PARTS SHALL BE PURCHASED FROM MHI. 6. THE CASE OF PURCHASE THE PARTS, PLEASE INFORM THE PARTS ORDER No. AND NAME IN APPENDIX "H".

FIGURE 2-8-1 Induced Draft Fan Mitsubishi

DESCRIPTION

NEUTRAL

90

o

36

24 D-D

ITEM

General

LINKAGE MECHANISM ASSEMBLY 2-16

Chapter 2

NORMAL LENGTH 22 21 40 35 13

37

33

19

16

34

34 30

17

31

c

15 20 23

16

12

ITEM

A

6 16

3

16

2

15

39 29 25 EXTENSION

36 5

27 24

11 b

3 15

15 a

13

30

14

20 23

34

19

"A"

33 18

35

1 26

38 NORMAL POSITION

4

16 16

A

COMPRESSION

"B" ALARM POSITION

ALARM POSITION OPEN(CLOSE)

MAX. DISPLACEMENT

COMPRESSION

CLOSE(OPEN)

EXTENSION

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 a

12

8

21

12 22

Rev.003

MAX. DISPLACEMENT

9

32 28

21 24

25

10

A-A

MM-M02.02

ALARM POSITION

21

22

MPTD-3-0033-2

"C"

12 22 40

8

7

b c

ALARM POSITION

OPEN(CLOSE)

CLOSE(OPEN)

Induced Draft Fan Mitsubishi

DESCRIPTION BOLT M8x15 SPRING SEAT SPRING SEAT SPRING HOLDING FLANGE SWITCH MOUNT STOPPER LIMIT SWITCH SUPPORT STOPPER LINER LINER PACKING PACKING DISTANCE PIECE SHAFT SPRING BUSH CONNECTING ROD BOLT (PIN) SPHRICAL JOINT BOLT M10x25 BOLT M6x20 WASHER M6 SPRING WASHER M10 SPRING WASHER M6 SPRING WASHER M4 WASHER M8 MACHINE SCREW M6x16 MACHINE SCREW M4x40 MACHINE SCREW M4x10 NUT M20 NUT M24 NUT M4 NUT M16 SPLIT PIN SPLIT PIN O-RING P20 PIN LIMIT SWITCH TERMINAL BOX BOLT M6x14 DETECTIVE CYLINDER LIMIT SWITCH COVER SPRING HOLDING FLANGE

NOTES 1. PURPOSE (1) DETECTION OF MB. STICKING AND PROTECT OF LINKAGE ASS'Y. 2. MECHANISM OF MOVING BLADE STICKING DETECTOR (1) "A" : NORMAL OPERATION POSITION. (2) "B" : MB STICKING OR LINKAGE ASS'Y IS ABNORMAL POSITION AT MB CLOSE OPERATION. (3) "C" : MB STICKING OR LINKAGE ASS'Y IS ABNORMAL POSITION AT MB OPEN OPERATION. 3. REPLACE PARTS SHALL BE PURCHASED FROM MHI. 4. THE CASE OF PURCHASE THE PARTS, PLEASE INFORM THE PARTS ORDER No. AND NAME IN APPENDIX "H".

FIGURE 2-8-2

General

DETECTED BY MB. STICKING DETECTOR

BLADE STICKING DETECTOR 2-17

Chapter 2

10

9 37

ITEM

36

K

K

34

21

18

23 30 40 A

E A

E

24 29

2

16

OIL SUPPLY OF BEARING

B

OIL SUPPLY OF BEARING

CL OF SHAFT

8 38

MOTOR SIDE B-B

17 C

1 D

22

16

G

G

3

F DET. D

24 29 D

ROTATION

F

44

43

42 28

H

OIL SURFACE

45

46

11

10 9

D 48

47

CASING DRAIN OUTLET

OIL RETURN

D

B

C

J 51

K-K 15 14 13 12 C-C

A-A

41 35

35

BEARING BOX

3

PIN

4

PIPE FOR OIL RETURN

5

SEAT FOR OIL RETURN

6

SEAL PACKING

7

PACKING

ADJUSTABLE RING

8

PACKING

9

SPECIAL BOLT

10

STOPPER

11

BUSH

12

ADJUSTABLE LINER t=4.5

13

ADJUSTABLE LINER t=0.5

14

ADJUSTABLE LINER t=0.2

15

ADJUSTABLE LINER t=0.15

16

O RING

17

O RING

18

O RING

19

SEAL RING

20

O RING

21

O RING

22

O RING

23

BOLT

24

SOCKET HEAD BOLT

25

SOCKET HEAD BOLT

26

HEXAGONAL HEAD BOLT

27

SOCKET HEAD BOLT

28

PARALLEL PIN

29

WASHER

30

WASHER

31

WASHER

32

WASHER

33

WASHER

34

PLUG

35

PLUG

36

BEARING BOX COVER (DE)

37

BEARING BOX COVER (NDE)

38

INSPECTION HOLE COVER

39

LUB.OIL STRAINER

40

BUSH

41

O RING

42

DE BEARING (ROLLER)

43

NDE BEARING (ROLLER)

44

NDE BEARING SET (BALL)

45

BEARING SPACER 1

46

BEARING SPACER 2

47

OIL DISTRIBUTOR RING 1

48

OIL DISTRIBUTOR RING 2

49

SLEEVE

50

LABYRINTH SEAL RING

51

MAIN SHAFT

19 50 49

27 33

26 32

39

5

Rev.003 MM-M02.02

DESCRIPTION

1 2

35 39

20

20 F-F

25 31 7

BEARING OIL RETURN FLOW

E-E

General

DET. G

6

4 DET. J

DET. H

MPTD-3-0067

FIGURE 2-9 Induced Draft Fan Mitsubishi

BEARING BOX ASSEMBLY

2-18

Chapter-2

PI 10

PI 9

TE 4

TE 2

TI 8

FT 1

XE 1

TE 3

PT 1 TI

BUTTERFLY VALVE

TE

TE 1

BUTTERFLY VALVE

PI DPI

BF-2

BF-‚ P

PT 03HNC01AN101 (03HNC01AN102)

FT

IDF

XE PS

MOTOR

ZS LS

20A

25A 25A 65A 25A

15A 20A 15A 15A 20A

LI

65A

LUBRICATING OIL RETURN

BLADE STICKING DETECTOR OIL SEAL LEAK OIL

20A

20A

ZS 2

PILOT LEAK OIL

U-SEAL

U-SEAL CONTROL OIL LEAK OIL

20A

F-4

40A

PI 3

PS 5

20A

PS 4

25A

100A

40A

25A 40A

40A

PS 1

PS 6

20A

20A

FOR MAINTENANCE

100A

PS 2

LUBRICATING OIL SUPPLY

PS 3

LOCAL PANEL

40A

A-1

FOR MAINTENANCE

40A

CONTROL OIL SUPPLY

DU-1

CONTROL OIL RETURN

40A ZS 1

PI 6

F-5

PI 2

PI 1

PRESSURE GAUGE

TI 7

XE 2

PRESSURE SWITCH

M

TI 6

DPI 7

INSTRUMENTS LIST

THERMOMETER

DPI 8

EXPLANATION OF SYMBOL DESCRIPTION INSTRUMENT(FIELD MOUNTED) LOCAL PANEL MOUNTED INSTRUMENT CONTROL AND/OR DISPLAY FUNCTION IN DCS CONTROL AND/OR DISPLAY FUNCTION IN PLC THERMOMETER (LOCAL) THERMOCOUPLE PRESSURE GAUGE (LOCAL) DIFFERENTIAL PRESSURE GAUGE (LOCAL) 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

THERMOCOUPLE

M TI 5

SYMBOL

LEVEL LEVEL LIMIT GAUGE SWITCH SWITCH

D-2 03HNC01AN202 (03HNC01AN204) B-2

250A

D-1 03HNC01AN201 (03HNC01AN203) B-1

SEAL AIR

250A

250A

General

03HNC01CP311 (03HNC01CP321) 03HNC01CP312 (03HNC01CP322) 03HNC01CP313 (03HNC01CP323) 03HNC01CP314 (03HNC01CP324) 03HNC01CP315 (03HNC01CP325) 03HNC01CP316 (03HNC01CP326) 03HNC01CP711 (03HNC01CP721) 03HNC01CP712 (03HNC01CP722) 03HNC01CP317 (03HNC01CP3270 03HNC01CP318 (03HNC01CP328)

DESCRIPTION IDF CONTROL OIL PUMP 3 A1/B1 OUTLET IDF CONTROL OIL PUMP 3 A2/B2 OUTLET IDF CONTROL OIL SUPPLY PRESS. IDF LUBRICATING OIL COOLER INLET IDF LUBRICATING OIL COOLER OUTLET LUBRICATING OIL SUPPLY PRESS. PILOT BOX SEAL DIFFERENTAL PRESS. BEARING BOX SEAL DIFFERENTAL PRESS. IDF SEAL AIR FAN 3 A1/B1 AIR FILTER OUTLET IDF SEAL AIR FAN 3 A2/B2 AIR FILTER OUTLET

SET POINT

7.50 ~ 7.85 MPa

0.16 ~ 0.19 MPa

RANGE 0~15MPa 0~15MPa 0~15MPa 0~1.0MPa 0~1.0MPa 0~0.4MPa 0 ~ 10kPa 0 ~ 10kPa -2~0kPa -2~0kPa

SYMBOL PI-1 PI-2 PI-3 PI-4 PI-5 PI-6 DPI-7 DPI-8 PI-9 PI-10

0~10MPa 0~10MPa 0~10MPa 0.02~0.2MPa 0.02~0.2MPa 0.02~0.2MPa

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

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

TI-1 TI-2 TI-3 TI-4 TI-5 TI-6 TI-7 TI-8

0~150 C 0~150 C 0~150 C 0~150 C

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

0~300um(P-P) l 0~300um(P-P) l

XE-1 XE-2

03HNC01CP211 (03HNC01CP221) 03HNC01CP212 (03HNC01CP222) 03HNC01CP213 (03HNC01CP223) 03HNC01CP214 (03HNC01CP224) 03HNC01CP215 (03HNC01CP225) 03HNC01CP216 (03HNC01CP226)

CONTROL OIL PRESS. NORMAL INTERLOCK

03HNC01CT311 (03HNC01CT321) 03HNC01CT312 (03HNC01CT322) 03HNC01CT313 (03HNC01CT323) 03HNC01CT314 (03HNC01CT324) 03HNC01CT315 (03HNC01CT325) 03HNC01CT316 (03HNC01CT326) 03HNC01CT317 (03HNC01CT327) 03HNC01CT318 (03HNC01CT328)

IDF LUBRICATING OIL COOLER INLET IDF LUBRICATING OIL COOLER OUTLET COOLING WATER INLET OIL TANK IDF SEAL AIR FAN 3A1 / B1 BEARING N i ON-MOTOR SIDE j IDF SEAL AIR FAN 3A1 / B1 BEARING M i OTOR SIDE j IDF SEAL AIR FAN 3A2 / B2 BEARING N i ON-MOTOR SIDE j IDF SEAL AIR FAN 3A2 / B2 BEARING M i OTOR SIDE j

03HNC01CT011 (03HNC01CT021) 03HNC01CT012 (03HNC01CT022) 03HNC01CT013 (03HNC01CT023) 03HNC01CT014 (03HNC01CT024)

RADIAL BEARING TEMPERATURE HIGH ALARM(MOTOR SIDE)

03HNC01CY011 (03HNC01CY021) 03HNC01CY012 (03HNC01CY022)

BEARING VIBRATION HIGH ALARM (1ST. BLADE SIDE) BEARING VIBRATION HIGH ALARM (2ND. BLADE SIDE)

03HNC01CG211 (03HNC01CG221) 03HNC01CG212 (03HNC01CG222)

BLADE ANGLE 0% POSITION INTERLOCK BLADE STICKING ALARM

FULL CLOSE ON

ZS-1 ZS-2

03HNC01CL211 (03HNC01CL221)

OIL TANK LEVEL LOW ALARM

MIN. OIL LEVEL LOWER THAN 50mm ON

LS-1

03HNC01CL311 (03HNC01CL321)

OIL TANK LEVEL

MAX. OIL LEVEL 1400 MIN. OIL LEVEL 650

LI-1

03HNC01CF101 (03HNC01CF151)

IDF 3A/3B FLUE GAS FLOW

FT-1

03HNC01CP101 (03HNC01CP151)

IDF 3A/3B SUCTION FLUE GAS DRAFT

PT-1

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

THRUST BEARING TEMPERATURE HIGH ALARM(MOTOR SIDE)

P> = 5.88 MPa ON P< = 5.39 MPa ON P< = 2.45 MPa ON > 0.14 MPa ON P= P< = 0.13 MPa ON P< = 0.09 MPa ON

T> =100 T> =100 >100 T= >100 T=

CON CON CON CON

V> = 130um l ON V> l ON = 130um

F-6

PI 4

03HNC01AC101 (03HNC01AC102) C-1

PI 5

03HNC01AP201 (03HNC01AP203)

P

TI 2

03HNC01AP202 03HNC01AP204

P-2

LS 1

TI 4

OIL DRAIN

P P-1 AIR BREATHER

TI 1

M

WATER DRAIN

M

TI 3 OIL SUPPLY PLUG

EQUIPMENTS LIST SYMBOL F-1

LI 1

T-1 03HNC01BB101 (03HNC01BB102)

F-3

MM-M02.02

Rev.003

65A

OIL UNIT

65A

40A

F-2

COOLING WATER

MPTD-3-0024

P-1 P-2 F-1 F-2 F-3 F-4 F-5 F-6 C-1 A-1 T-1 DU-1 B-1 B-2 BF-1/2 D-1/2

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

LUBRICATING OIL DOUPLEX STRAINER IDF LUBRICATING OIL COOLER ACCUMULATOR OIL TANK DRIVE UNIT IDF SEAL AIR FAN 3 A1/B1 IDF SEAL AIR FAN 3 A2/B2 IDF SEAL AIR FAN SUCTION FILTER IDF SEAL AIR FAN SUCTION AIR DAMPER INDUCED DRAFT FAN IDF MOTOR

FIGURE 2-10 Induced Draft Fan Mitsubishi

REMARKS 7.85 MPax 135 /min AC 416 V x 50 Hz 30 kW x 6P

100 mesh 150 mesh 150 mesh 20u l 20u l 200 mesh 10 TON/Hr 60 1400 Torque 102 N-m 80m3/min x 650 mmAq x 15 kW x 3000 rpm 10u l SWING CHECK VALVE 3 45400 m /min x 970 mmAq 8580kW x 8P

IDF LUBRICANT AND CONTROL OIL SYSTEM P & I D

2-19

General

MM-M02.02

Rev.003

Chapter 2

FIGURE 2-11

Induced Draft Fan Mitsubishi

FORM FLEX COUPLING

2-20

Chapter 3

Specifications

C h a p t er

3 Specifications TABLE 3-1

INDUCED DRAFT FAN

Subject

Specifications

Equipment number

03HNC01AN101, 03HNC01AN102

Quantity

2 sets

Fan

Coupling Bearing

Manufacturer

MHI

Model

ML-H2-R200/375

Type

Axial Fan, Blade Pitch Control

Manufacturer

Daido Precision Industries Ltd.

Type

Flexible Coupling

Manufacturer

JTEKT

Type

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

Basic load ratings (kN) Dynamic

Major Material

Weight (approximately)

Static

NU364AY3CS240

1970

2880

83A385ADT/41

1990

10100

NJ364AY3CS24041

1970

2880

Casing

General carbon steel

Moving Blade

Cast steel

Rotor

Forged steel

Rotor Shaft

Forged steel

Bearing (Box/Body)

Cast iron/bearing steal & carburizing steel

Coupling

General carbon steel

Rotor

31.5 t

Suction casing

19.0 t (without insulation)

Impeller casing – upper half

12.0 t (including insulation)

Impeller casing – lower half

14.5 t (including insulation)

Rear casing – upper half

3.6 t (including insulation)

Rear casing – lower half

5.0 t (including insulation)

Diffuser

18 t (including insulation)

Design Rotating speed

735rpm

Blades

16

MM-M02.02

Rev.003

Design performance characteristics Direction of Rotation

Clockwise

Capacity (each fan)

45,400 m3/min

Inlet static pressure

-540 mm Aq (Gauge)

Outlet static pressure

430 mm Aq (Gauge)

Fluid

Flue Gas

Fluid temperature at inlet (design)

140°C

Fluid density (design)

0.8323 kg/m3

Induced Draft Fan Mitsubishi

3-1

Chapter 3

TABLE 3-2

IDF MOTOR

Subject

Specifications

Manufacturer

Hyundai Heavy Industries Co., Ltd.

Type

HRP3 1129-88E

Rated Output

8,580 kW

Rated Voltage

13,200 V

Rated Current

456.9 A

Frequency

50 Hz

Poles

8

Coupling

Direct

Rating

Continuous

Thermal Class

F

Maximum Ambient Temperature

40°C

Bearing

Split Sleeve

Total Weight (approximately)

41,500 kg

TABLE 3-3

Specifications

IDF CONTROL/LUBRICATING OIL UNIT

Subject Oil Specification

Specifications ISO VG 32

Electric Power

Power

AC 416V, 30kW, 1,000rpm

Control Oil Pump

Type

Vane Pump

Quantity

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

Capacity

135 L/min

Working Pressure

7.85 MPa

Type

Totally Enclosed Fan Cooled Type

Quantity

Two (2) sets

Oil Tank

Total Volume

1,400 l

Oil Cooler

Type

Shell and Tube

Quantity

One (1) set

Water quantity

10 Ton/H

Oil Pump Motor

150 mesh

Return Oil Strainer

100 mesh

Lube Oil Duplex Strainer

200 mesh

Control Oil Pump Discharge Strainer

20 μ

Accumulator

60 l

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Rev.003

Control Oil Pump Suction Strainer

Induced Draft Fan Mitsubishi

3-2

Chapter 3

TABLE 3-4

Specifications

IDF SEAL AIR FAN

Subject

Specifications

Electric Power

Power

AC 416V, 15kW, 3000rpm

Seal air fan

Type

Centrifugal

Quantity

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

Capacity

80m3/min

Working Pressure

650mmAq

Type

Totally Enclosed Fan Cooled Type

Quantity

Two (2) sets

Motor

10 μ

MM-M02.02

Rev.003

Suction Filter

Induced Draft Fan Mitsubishi

3-3

Specifications

MM-M02.02

Rev.003

Chapter 3

FIGURE 3-1 Induced Draft Fan Mitsubishi

PERFORMANCE CURVE

3-4

Chapter 4

Preventive Maintenance

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 IDF 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. 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.).

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Rev.003

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.

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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), this is to be resolved by mutual agreement between the parties involved.

4.1.3 Isolation of EquipmentIt 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 or pad locked. In the case of mechanical isolation, the valves or other mechanical means of isolation (blinding), 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.

MM-M02.02

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

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4-2

Chapter 4

4.2

Preventive Maintenance

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)

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.

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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.

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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 and Main Bearing The rotor assembly, consisting of the rotor, the moving blades (two stages) 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 wheel resulting from erosion or damage to the wheel by foreign materials, or by dust adhering to the moving 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 130 µm (p-p) 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.

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

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Chapter 4

Preventive Maintenance

Bearing problems generally result from lubricating oil problem and/or excessive vibration. Emphasis is to be given to checking the equipment operating parameters, (e.g. oil supply, oil temperature, bearing temperature and oil tank levels). Bearing temperature must not exceed 100°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 and shortage of sealing/cooling air 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.

b) 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 reference.

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

c)

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 this event should be recorded for inclusion in the annual overhaul program.

Rev.003

d)

Control/Lubricating Oil System

MM-M02.02

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

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4-5

Chapter 4

Preventive Maintenance

The condition of the control oil / lube oil strainer is to be monitored. When there is a high differential pressure across a control oil strainer the stand by, control oil strainer should be placed in service and the defective strainer, should be replaced immediately to be an effective standby. If the lube oil strainer is clogged, change the standby line, or clean it. 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, and repair them after reducing oil pressure.

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 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

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The fan coupling is to be observed for any abnormal noise. Noise would be heard from the coupling if there is any damage to the coupling element or the coupling bolts. Noise is also generated if the coupling rubs the coupling cover.

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4-6

Chapter 4

g)

Preventive Maintenance

Seal Air Fan System The seal air fan is to be monitored for smooth operation, air leakage and vibration. Any apparent problem is to be immediately resolved. It is most important to keep the seal differential pressure (more than 1kPa). If it is not enough seal differential pressure, gas is leaking into the fan inner casing and damage the rotor and bearing. Seal air fan should be change over the stand by fan and clean the suction filter, periodically. It is important to follow the lubricating oil requirements such as, the frequency of replacement of the lubricant as per the manufacturer’s instruction or based on the analysis result received from the laboratory.

MM-M02.02

Rev.003

For further details, please refer to the Vendor’s manual, Appendix.

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4-7

Chapter

TABLE 4-1

No.

1

Description

Rotor main bearing

4 Preventive Maintenance

ROUTINE MAINTENANCE CHECKLIST

Major Check Item

Check Method

Check Reference

Vibration

Permanent instruments

Less than 130 μm

Temperature

Permanent instruments

Not exceeding 100ºC

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 deposit. Check and adjust shaft alignment. Check for any foreign material in the lubricating oil. Rotate the rotor assembly by hand and observe any rubbing noise.

Daily

Replace bearings, if the vibrations is not decreased after field balancing. 2

Coupling

Abnormal noise

Visual and audible

No abnormal noise

No contact between the coupling and coupling cover.

Check and replace coupling element, coupling bolts, etc., if damaged and then re-check alignment. Adjust coupling cover clearance.

3

Moving Blade Regulating Mechanism

Smooth operation

Permanent Instruments

No alarm

Rectify defective regulating mechanism and linkage mechanism after shutdown if IDF can’t be controlled

4

Casing

Check for any gas leakage

Visual and audible

No apparent gas leakage

Tighten bolts or patch weld after shutdown.

Beware of rotating part during maintenance. Please refer to the vendor’s manual.

Daily

Daily

Daily

MM-M02.02

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Rubbing contact with the coupling cover

Audible

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4-8

Chapter

4 Preventive Maintenance

Continued from previous page… TABLE 4-1

No.

5

Description

Seal Air Fan

Major Check Item

Bearing vibration

Bearing temperature

Check Method

ROUTINE MAINTENANCE CHECKLIST

Check Reference

Portable vibrometer

Less than 40 µm

Permanent instruments

Less than 80°C

Action to be Taken (if beyond acceptable limit) Shut down and check for bearing damage. Check for any foreign material in the lubricating oil.

Remarks

Please refer Vendor’s manual

Rotate the rotor assembly by hand and observe for any rubbing noise.

Recommended Maintenance Frequency Depends on condition

Daily

Replace bearing, if damaged. Inlet filter

NA

NA

Changeover to standby fan and check filter. Clean the filter.

Abnormal noise

Audible

No abnormal noise

If vibration or temperature is observed, shutdown and check the fan.

Seal differential pressure

Permanent instruments

More than 1 kPa

Changeover to standby fan and check filter. Clean the filter, if clogged.

Every 3 months

Daily

Daily

Adjust butterfly valve Control/Lubricating Oil pressure Oil System

MM-M02.02

Rev.003

6

Induced Draft Fan Mitsubishi

Permanent Instrument

Control oil supply pressure 7.50 to 7.85 MPa Lube oil supply pressure 0.16 to 0.19MPa

Check the lube oil pump discharge pressure , pressure control valve, oil temperature, oil flow and the operation of the stand by pump.

Oil pump bearing temperature

Touch/ portable thermometer

No appreciable temperature rise

Check the cause of temperature rise

Oil pump shaft oil leak

Visual

No leak

Replace oil seal

For more details, please refer to Vendor’s manual

Daily

4-9

Chapter

4 Preventive Maintenance

Continued from previous page… TABLE 4-1

No.

Description

Major Check Item

6 Control/Lubricating Oil pump shaft (Cont) Oil System rotating condition Oil strainer

Check Method

Visual/audible

ROUTINE MAINTENANCE CHECKLIST

Check Reference

No abnormal noise No abnormal trembling

Permanent instrument

Not clogged Color of indicator on the top of the strainer is not red (replacement), but green (Normal) (Control oil pump discharge strainer) Diff. press. Less than 0.1MPa

Action to be Taken (if beyond acceptable limit) Investigate and take action, to normalize the condition, such as exchange of bearings.

Remarks

Recommended Maintenance Frequency

For more details, please refer to Vendor’s manual

Change over the stand by control oil pump line and replace the clogged strainer. (Control oil pump discharge strainer). Change over the standby strainer and clean the blocked strainer in maintenance. (Lubricating oil duplex strainer).

(Lubricating oil duplex strainer) Visual

No leak

Exchange O-ring /Further tightening

Permanent instrument

Normal oil level

Investigate and top up oil level

Oil tank oil temperature

Permanent instruments

Not to exceed 70oC

Investigate and take action to reduce the temperature.

Oil cooler water flow

Visual, Permanent instrument

Rated flow

Investigate and normalize the flow

Visual

No leak of water or oil

Further tightening

Rev.003

Level gauge

Daily

Repair of any leakage of water into the system.

MM-M02.02

Exchange of gaskets Visual, Permanent instrument

Induced Draft Fan Mitsubishi

Oil temperature of oil cooler not to exceed 70oC

Cooling water check Disassembly and clean up of cooler

4-10

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), 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 spares and consumables used. These records will be used for future reference and spare parts replenishment.

MM-M02.02

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.

Induced Draft Fan Mitsubishi

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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, which could cause serious equipment damage. Visual inspection of the rotor wheel and moving blades is to include checks for erosion, dust adherence, or 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 wheel, moving blades (two stages) and rotor shaft clearances with the respective stationary parts are to be checked against the appropriate tolerances as indicated in Figure 4-1, Clearance Drawing of IDF. 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 (two stages) are to be operated for 100% opening and full closing positions with the moving blade regulating mechanism to ensure that all moving blades(two stages) move uniformly. The moving blade support bearing of any sticking blade is to be inspected and replaced if found defective. The grooves on the rotor shaft corresponding to the bearing box labyrinth seals on both the drive and non-drive ends 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.

MM-M02.02

Rev.003

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.

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Chapter 4

Preventive Maintenance

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. Prior to disassembly, the bearing box is to be inspected for any trace of oil leakage through the shaft. Both before and after disassembly, check and record the seal clearance between the oil baffle assemblies and the rotor shaft. 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 and repaired or replaced as required. 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 disassembly, the moving blade regulating mechanism is to be inspected for any trace of oil leakage from the servo cylinder and pilot valve head that might have occurred during normal operation. The inner surface of the servo 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 seal rings and the servo cylinder packing are to be inspected for damage and replaced with new if found defective. Control oil inner piping (flexible hose) 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 greasing of the various moving parts are to be performed. On completion of the maintenance work the linkage assembly is to be checked for smooth operation with the control drive. The 90° movement of the power cylinder is to be adjusted for the moving blade operation range of –40° to +16.3° (indicated on the rotor).

d)

Casing

MM-M02.02

Rev.003

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, welding a wear plate in position should be considered as a solution to the problem. Checks for corrosion are to be performed at this time. Induced Draft Fan Mitsubishi

4-13

Chapter 4

Preventive Maintenance

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

e)

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 cleaned and 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 details, please refer to the vendor’s manual in Appendix F.

f)

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

g)

Seal Air Fan System The seal air fan is to be inspected for any casing or impeller damage. Any apparent problem is to be rectified. Rotor balancing must be done if any repair work is done. Replace the suction filters.

MM-M02.02

Rev.003

For more details, please refer to the vendor’s manual in Appendix F.

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4-14

Chapter 4

TABLE 4-2 No. 1

Descriptio n Rotor

Major Check Item

Check Method

ANNUAL OUTAGE MAINTENANCE CHECK LIST

Check Reference

Action to be Taken (if beyond acceptable limit)

Remarks

Wear, cracks

Visual

No appreciable wear No crack

Replace the rotor assembly Rebalance

Every rotor overhaul (4 years)

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.)

Every rotor overhaul (4 years) Adjusting clearance is carried out after checking of correctly rotor assembling.

Replace the rotor

Every bearing overhaul (every 8 years (if have spares), (4 years if have not spares))

2

Rotor Shaft Wear, cracks

Visual

No appreciable wear No crack

3

Moving Blades

Outer casing clearances

Measurement

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

Wear, crack

Visual , Measurement

*1

Wear less t than 10%

Preventive Maintenance

Replace the blades

*2

PT check*2

Inspection Date

Inspector

Results

Every casing overhaul (4 years)

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

2

Tightness of blade fixing bolts

Visual*

Not loose (in caulked condition)

Tighten the blade fixing bolts and caulk

Axial movement

Measurement

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

Adjusted by shim between the moving blade support bearing and nut for moving blade shaft.

MM-M02.02

Rev.003

Design: L=144mm No crack

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Every rotor overhaul (4 years)

4-15

Chapter 4

Preventive Maintenance

Continued from previous page. TABLE 4-2 No.

Descriptio n

Major Check Item

Check Method

ANNUAL OUTAGE MAINTENANCE CHECK LIST

Check Reference

Action to be Taken (if beyond acceptable limit)

Remarks

3 (Cont)

Moving Blade Bearing

Security

NA

NA

Replace

Recommended to replace the bearing assembly every 4 years

4

Rotor seal and Packing

Wear

Visual and audible

No rubbing marks

Replace the shaft seal and adjust clearance

Every casing overhaul ( 4 years)

Clearance

Measurement

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

Adjust clearance

Every casing overhaul ( 4 years)

Coupling

Deformation, crack and damage

Visual

No defective parts

Replace or repair

Every coupling overhaul (4 years)

Alignment

Measurement

Refer to Appendix D Realign within specified Every coupling overhaul criteria (4 years)

Rubbing with the coupling cover

Visual and Audible

No contact between Adjust the coupling the coupling and cover position coupling guard

Every coupling overhaul (4 years)

NA

NA

Na

Replace

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

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

Replace

Every rotor overhaul (every 4 years)

5

6

Main bearing

Inspector

Results

MM-M02.02

Rev.003

Bearing box Seal clearance Measurement

Inspection Date

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4-16

Chapter 4

Preventive Maintenance

Continued from previous page. TABLE 4-2 No. 7

MM-M02.02

Rev.003

8

Major Check Item

Description Casing

Check Method

ANNUAL OUTAGE MAINTENANCE CHECK LIST

Check Reference

Action to be Taken (if beyond acceptable limit)

Remarks

Wear, cracks

Visual measurement

No appreciable wear

Repair the casing

Casing to blade clearance should not be exceed tolerance limits.

Debris

Visual

No cracks

Remove debris and clean the fan casing inside

Every inner inspection (2 years)

Moving Blade Pilot valve and Measurement Regulating sleeve clearances Mechanism

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

Replace the pilot valve Every rotor overhaul (4 and sleeve years) Recommended to replace the cylinder, pilot valve & sleeve every 8 years (if have spares), 6 years (if have not spare)

Wear of servo cylinder, sleeve

Measurement

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

Replace

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

Every inner inspection (2 years)

Moving blade adjustment

Visual, Measurement

Adjust blades position from -40° to +16.3°

Adjust connecting rod length

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

Replacement NA of consumable parts

NA

Replace

Every rotor overhaul (4 years) Refer to Appendix H

Replacement NA of consumable parts-oil hoses

NA

Replace

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

Induced Draft Fan Mitsubishi

Inspection Date

Inspector

Results

4-17

Chapter 4

Preventive Maintenance

Continued from previous page. TABLE 4-2 No.

Description

Check Method

Check Reference

Action to be Taken (if beyond acceptable limit)

Remarks

Grease up

NA

NA

NA

Every year

Replacement of consumables

NA

NA

Replace

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

Control/ Oil condition*1 Lubricating Oil System

Visual

Replace oil every annual outage maintenance

NA

Wear or damage of oil pump 3 components*

Visual

No wear or damage Replace defective components

For detail, refer to Vendor’s manual *1 interval for every year *2 interval for every 2years *3 interval for every 4 years

Damage of control oil 2 filters*

Visual

No damage

Replace filter

Accumulator bladder*2

Visual Pressure gauge

No ageing, cracks or damage

Replace bladder

Oil cooler leakage*3

Visual Hydraulic test

No leak

Plug the leaking parts (packing and O-rings)

Oil cooler protecting 2 Zinc*

Measurement

The length is not below 1/4 ~ 1/3 of original length

Replace with a new one

9 Linkage mechanism

Inspection Date

Inspector

Results

MM-M02.02

Rev.003

10

Major Check Item

ANNUAL OUTAGE MAINTENANCE CHECK LIST

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4-18

Chapter 4

(Continued from previous page

)

TABLE 4-2 No .

Major Check Item

Description

Check Method

Check Reference

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

Remarks

Tightness of base bolt

Visual

Not loose

Tighten the base bolts

Interval is every 2 years

Internal parts

Visual

No debris

Remove debris and clean inside parts

Every overhaul is every 4 years

Bearing

N/A

N/A

Grease

Recommended to replace every 4 years

Filter

Visual

No clogging

Clean or replace the Every overhaul filter 4 years

Damper

Visual

No debris

Remove debris and clean

Inspection Date

Inspector

Results

Every overhaul 4 years

MM-M02.02

Rev.003

11 Seal Air Fan

Preventive Maintenance

Induced Draft Fan Mitsubishi

4-19

4.0~9.5 4.0~10.5)

Preventive Maintenance

(

(

4.0~9.5 4.0~10.5)

Chapter 4

AXIAL MOVEMENT OF MOVING BLADE 0~0.1 (0~0.3)

AXIAL MOVEMENT OF MOVING BLADE 0~0.1 (0~0.3)

MOTOR SIDE FLOW

2.16~3.69

0.29 ~0.45

84.2+0.5

2.16~3.69 3.0~9.0 (3.0~15.0)

0.29 ~0.45

0

1.41~2.19

0

0.45~0.55 ( 0.45~0.83) 0.35~0.53

0.02~0.21 (0.02~0.32)

0.02~0.21 (0.02~0.32)

0~0.05

0~0.05

0

0.02~0.17 (0.02~0.26) 7 +0.25

3.0~9.0 (3.0~15.0)

3.0~9.0 (3.0~15.0)

1.41~2.19

3.0~9.0 (3.0~15.0)

0.02~0.17 (0.02~0.26)

0

0

0.02~0.17 (0.02~0.26)

0.02~0.17 (0.02~0.26)

0

A 0

ROTATION

40.8+0.5

0.05~0.13 (0.05~0.20)

7 +0.25

0.65~0.80

21.7

MM-M02.02

Rev.003

MPDT-3-0069

A-A

1.55~1.75

A

CL OF 1ST M/B

CL OF 2ND M/B

1.55~1.75

0.65~0.80

0.04~0.07 0.04~0.11

0.04~0.07 0.04~0.11

0.045~0.055 (0.045~0.065)

21.7

NOTES MARK ( ) ARE CLEARANCE ON RADIUS. ** ~ ** : DESIGN VALUE (** ~ **) : ALLOWANCE VALUE (TENTATIVE VALUE) ALLOWANCE VALUE ARE SET IN FIRST ANNUAL OUTAGE MAINTENANCE IN REFLECTION OF CONDITION AFTER PLANT OPERATION ETC..

FIGURE 4-1 Induced Draft Fan Mitsubishi

IDF CLEARANCE DETAILS

4-20

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, spares 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 IDF are the casing, blade pitch control mechanisms, bearings and the blade assembly. Except for the bearing replacement all other disassembly and assembly of the IDF parts can be done in situ. 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 reassemblies are as follows:

Note MHI recommends that Disassembly and Reassembly of IDF is carried out under MHI supervision.

5.1

IDF Disassembly and Reassembly

CAUTION Prior to carrying out any maintenance, confirm that all equipment is shut down and that all isolations are in place.

a)

Preparation If IDF disassembly becomes necessary, all associated equipment is to be mechanically and electrically isolated and an authorized clearance and work permit shall be in place prior to the commencement of work. The following points are also to be considered when preparing for disassembly and reassembly: Have all necessary drawings (assembly drawings, sectional drawings, 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.

MM-M02.02

Rev.003



Induced Draft Fan Mitsubishi

5-1

Chapter 5

Disassembly and Reassembly



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.



The electrical breaker must switched off and locked at both locations and the key must be retained by the Charge Engineer.



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

Special tools are listed in Appendix C.

b)

Disassembly

CAUTION Don’t sit or stand on a rotor during disassembly.

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 ease of identification during reassembly. The disassembly procedure is described as follows: Refer to Figures 2-3, 2-4, 2-5, 5-1A and 5-1B.

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

CAUTION Take care not to fall while entering the casing.

MM-M02.02

Rev.003

Use the safety belt when entering inside the casing through the manhole.

Induced Draft Fan Mitsubishi

5-2

Chapter 5

Disassembly and Reassembly

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

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

When entering inside the fan, take precautions not to get trapped.

CAUTION Special care is to be taken when you work in the fan casing (like falling down of some thing above, slipping due to oil etc). Move the moving blades (two stages) to the full close position before starting disassembly of the IDF. Take care not to be close to moving blade when direction is changing.

2

Enter the diffuser inner casing through the diffuser inner casing manhole (79).

3

Remove the rear inner casing manhole (57).

4

Remove the bolts jointing the diffuser casing and the rear inner casing upper (52IU) and the bolts the securing the horizontal joint of the rear inner casing (52IU & 52IL).

5

Remove the bolts securing the seal plate for rear casing (56) from the rear inner casing (52I).

6

Remove insulation from around the joints of the impeller casing (51) upper and the rear casing upper (52).

Rev.003

1

Note Impeller casing (lower) and rear casing (lower) joints are seal

MM-M02.02

welded. Upper impeller and rear casings are not seal welded.

Induced Draft Fan Mitsubishi

5-3

Chapter 5

7

Disassembly and Reassembly

Remove the band for casing (54) provided between the suction casing (50) and impeller casing (51) by loosening the horizontal bolts first and then removing the vertical bolts.

CAUTION Special care is to be taken when moving blade operate (Pinch in the moving blade). 8

Remove the bolts securing the impeller casing upper (51U) and the rear casing upper (52U) including the horizontal flange joints. Remove the bolts between the rear casing and (52) diffuser (53).

9

Clean the inside of the fan casing before disassembly, to prevent the entry of any foreign material into the bearing box (26 of figure 2-3) and the servo cylinder (39 of figure 2-3).

10 Refer to Figures 5-1A & 5-1B. Using a jack up bolt, remove the impeller casing upper (51U) and the rear casing (52U) separately with their respective inner casings and transport them to the lay down area.

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. 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.

MM-M02.02

Rev.003

Wear the eye protect during oil line removal.

Induced Draft Fan Mitsubishi

5-4

Chapter 5

Disassembly and Reassembly

Oil line removal Refer to Figure 2-3. 11 Remove the connecting pin and disconnect the linkage mechanism from the pilot valve (30). Refer to section 5.4.

CAUTION Remove the oil connections only after depressurizing the system to atmospheric pressure. 12 Remove the control oil inner pipings (flexible hose) (41) from pilot valve (30) of control oil supply, control oil return, pilot leak and oil leak line. 13 Cover the openings of oil lines immediately with cloth to prevent the entry of dust.

CAUTION Removing the pilot valve from the rotor is carried out in the casing.

Pilot valve removal Refer to Figure 2-7 & 5-2. 14 Remove the oil cover for pilot leak (43) from the pilot valve by withdrawing screw (42) and washer (30). 15 Remove the bolts and washer (24 & 32) of cover (7). 16 Slowly withdraw the pilot valve (3) together with the joint (8), the bearing (22), the scroll (14) and the cover (7). 17 Provide temporary covers for the opening of the servo cylinder (1).

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.

Rev.003

Refer to Figures 2-7 and 5-2. The pilot valve (3) dismantling is done in the following steps:

MM-M02.02

(i)

Induced Draft Fan Mitsubishi

Remove the retaining rings (34) on either side of the scroll (14). Slide the pilot valve (3) with the scroll (14) and bearing (22).

5-5

Chapter 5

Disassembly and Reassembly

(ii)

Remove the retaining ring (35) and the bearing (22) from the scroll (14).

(iii)

Remove the set screw (27) and then the scroll. Remove the spring pin (33) from the pilot valve shaft.

(iv)

Remove the cover (7) with oil seal (23) and floating ring (15) from the pilot valve (3)

(v)

Remove the retaining rings (36) on either side of cover

(vi)

Remove the floating ring (15), the oil seal (23) and O ring (56)

(vii)

Remove the bolts (25) and spring washer (31). Discard the packing (9).

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

Coupling Removal: Refer to Figure 2-5 18 Enter the suction casing (50) through the suction casing manhole (77) and the suction inner casing manhole (78). 19 Remove the bolts (67&75 and 70&74) securing the suction inner casing upper (55IU). 20 Remove the suction inner casing upper (55IU) by using chain block. 21 Remove the suction inner casing lower (55IL) and place that in the suction casing (50). 22 Remove the coupling cover ass’y (58) by using chain block. 23 Fix the supporting tools with the impeller inner casing and suction casing to support the form flex coupling spacer as shown in Figure 5-8. 24 Remove the hub (fan side) (80) of the coupling. For details, refer to disassembly of coupling.

Rev.003

25 Remove the seal plate for rear casing (61 of Figure 2-3)

MM-M02.02

Take care not to drop the part to be lifted while rigging. If the part drops, it will damage the stationary equipment.

Induced Draft Fan Mitsubishi

5-6

Chapter 5

Disassembly and Reassembly

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

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

Lift the upper casing more than 1.8m high from the horizontal flange to avoid contact with moving blades.

Rotor Assembly & Bearing Removal:. Refer to Figure 2-3

CAUTION Don’t sit or stand on a rotor and bearing box during disassembly. 26 Disconnect and remove the lubricating oil supply pipes from the bearing box cover assembly (Refer to section 5.3). Cover the openings immediately with cloth to prevent the entry of foreign material. 27 Remove the temperature measuring elements and the vibration pickups from the bearing box. Install eye bolts in the threaded holes provided on the bearing box and rotor.

MM-M02.02

Rev.003

28 Connect the appropriate lifting gear to the lugs provided on the bearing box (26) and the eye bolts provided for the rotor (2).

Special care is to be taken in working near the rotor, there is possibility of pinching in the rotor. 29 Grind and remove the stopper (10 of Figure 2-9) welded (spot weld) to the bearing box fixing bolts (9 of Figure 2-9). Induced Draft Fan Mitsubishi

5-7

Chapter 5

Disassembly and Reassembly

30 Remove the bearing box fixing bolts (9 of Figure 2-9) and the dowel pins (28 of Figure 2-9).

CAUTION Take care not to lean on the rotor while removing the fixing bolts to avoid internal contact. 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. 31 Refer to Figure 5-1B. Adjust the slings to facilitate vertical lifting of the combined rotor and bearing assembly.

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

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

Don’t go near a rotor being lifted.

Pay attention not to work on the rotor while it is being lifted. This could be dangerous. 32 Slowly lift up the rotor assembly with the bearing box and transport it to the lay-down area. 33 When the rotor is lifted inside casing, cover the casing drain outlet pipe in the fan casing and also the pipe for oil return (4 of figure 2-9) with cloth/tape to avoid entry of foreign materials.

Rev.003

34 When the rotor assembly has been removed from the casing, it should be lowered into previously prepared supports so arranged as to support the bearing box.

CAUTION

MM-M02.02

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

Induced Draft Fan Mitsubishi

5-8

Chapter 5

c)

Disassembly and Reassembly

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. All contact surfaces are to be cleaned before starting reassembly and all gaskets are to be replaced. Before closing the manholes/access doors to the IDF an inspection is to be carried out to ensure that no material has been left inside.

Note Before installing the rotor assembly, Oil flushing is finished.

1

If disassembly of the 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 rotor 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

Refer to Figure 5-1B. 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 death or a severe injury. Install a new gasket (6 of figure 2.9) on the seat for lubricating oil return (5 of Figure 2-9).

6

Transport the rotor assembly with bearing box and servo cylinder to the fan casing, and lower it slowly into the casing so that the bearing box seats properly on the bearing box support. Do not forget to remove the temporary covers put on the bearing drain oil pipe lines before installing the fan assembly.

7

Remove the lifting equipment.

MM-M02.02

Rev.003

5

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

Induced Draft Fan Mitsubishi

5-9

Chapter 5

Disassembly and Reassembly

8

Measure the axial clearance of the rotor with the bottom halves of the impeller and rear inner casings.

9

Measure the radial clearance between the impeller and the rear inner casing seals.

10 Adjust the seals of the inner casings as required to achieve a clearance within the tolerance indicated in Figure 4-1. 11 Check that the rotor shaft to motor shaft coupling alignment is within the specified criteria (refer to Appendix D). 12 Install the bearing box parallel pin (Figure 2-9 (28)) and the bearing box fixing bolts (Figure 2-9 (10)). 13 After tightening the fixing bolts, replace and spot weld the previously removed stopper of the bearing box. 14 Install and secure the bearing box oil supply lines. 15 Install the vibration monitors and the temperature measuring elements onto the bearing box.

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

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 5-2. The pilot valve (3) reassembly is done in the following steps: (i)

Reassemble the pilot valve (3) with the bearing (22), scroll (14) cover (7) in the reverse order to disassembly.

MM-M02.02

Rev.003

Note:

(ii)

Install the cover (7) with oil seal (23) and floating ring (15) to the pilot valve(3).

(iii)

Install the scroll (14) with the spring pin (33) and the set screw (27). Note:

Induced Draft Fan Mitsubishi

Before the reassembly, replace all the consumable parts ( oil seal (23), floating ring (15), bearing (22), O ring and retaining ring)

Before the installing of scroll, set the retaining ring (34) of joint side (8).

5-10

Chapter 5

Disassembly and Reassembly

(iv)

Install the retaining rings (34) on either side of the scroll (14).

(v)

Install the retaining ring (35) and the bearing (22).

(vi)

Provide packing (9) onto the pilot valve head, install the joint (8) and secure it with spring washers (31) and bolts (25).

Refer to Figure 2-7 and 5-2. 16 Remove the temporary cover provided for the opening of the servo cylinder (1).

CAUTION Installing the pilot valve to rotor should be carried out in the casing. 17 Smear lubricating oil over the pilot valve assembly and slowly insert the pilot valve assembly on the servo cylinder (1) 18 Tighten the bolts (24) with washers (32). 19 Install the oil cover for pilot leak (43) and secure it with spring washer (30) and screw (42). 20 Connect the control oil inner piping (41 of Figure 2-3) to the pilot valve (3) of control oil supply, control oil return, pilot leak and oil leak line.

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

CAUTION Wear the eye protection in oil line assembly while working.

MM-M02.02

Rev.003

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

21 Start the oil pump, operate the moving blades 22 Check for the correct lubricating oil flow. 23 Check and confirm that the system is free from any control and lubricating oil leakage.

Induced Draft Fan Mitsubishi

5-11

Chapter 5

Disassembly and Reassembly

24 Ensure the moving blade stroke from 0% to 100% (from - 40° to +16.3°) 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 +16.3° 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 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) 25 After ensuring the moving blade stroke, readjust that control oil pressure is between 7.50 MPa and 7.85 MPa. 26 Connect the linkage mechanism to the joint (8 of Figure 2-7). 27 Adjust and calibrate the moving blade stroke from 0% to 100% (from 40° to + 16.3°) as per the procedure described below. (i)

Start the oil pump and check that the oil pressure is between 7.50MPa and 7.85 MPa.

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 + 16.3°. Adjust the linkage mechanism if required.

MM-M02.02

(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. Induced Draft Fan Mitsubishi

5-12

Chapter 5

Disassembly and Reassembly

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. 28 Install the suction inner casing (55IU, IL) and secured by bolt, nut (70) and spring washer (74). 29 Install the impeller casing upper (51U) and the rear casing upper (52U) and replace the liquid gaskets, if required by using special to (guide tool and nut).

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

30 Measure the impeller axial clearance of the rear and impeller inner casings. 31 Measure the radial clearance between the moving blades and the rear inner casing in the open position as indicated in Figure 4-1. 32 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.

MM-M02.02

Rev.003

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

35 Install and tighten the casing thread end taper pins (61&62) and all fasteners including those in the horizontal joints and install the band for casing (54). Induced Draft Fan Mitsubishi

5-13

Chapter 5

Disassembly and Reassembly

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

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

Special care is to be taken while lowering the casing to prevent damage to the moving blades and bearings. Keep sufficient distance while fixing the upper casing. If you are trapped between the casings, it could lead to death / or a serious injury

36 Restore or renew the insulation around the casing joints. 37 After a final inspection inside the casings, close all the manhole (57,77, 78, 79) 38 Install the coupling cover ass’y (58).

MM-M02.02

Rev.003

39 Return the fan to service.

Induced Draft Fan Mitsubishi

5-14

Chapter 5

BOILER FRONT

40t TRAILER (SUPPLIED BY OWNER)

MOTOR E3 38.1ton E4

7400

8800

2010

2840

3000

3550

1170

6550

6550

CL of ROAD E: 1160.440

2500

75t MOBILE CRANE (SUPPLIED BY OWNER)

1700 5750

E1

E2

OIL UNIT

5750

B1

B2

2500

A

7400

GL+12200

CL of BOILER E: 1210.840

2000

8800

GL+13287

1700

6550

A1

A2

GL+9532

UP

D.N

7000

GL+15842

2010

B

CL of I.D.F. N: 769.020

1300

2840

MONORAIL FOR IMPELLER CASING & ROTOR BOS GL+13700(I-600x190)

SILENCER

SILENCER

GL+9532

GL+12200

A' 3000 6550

IMPELLER CASING 12.0ton

REAR CASING 3.6ton

UP

A5

GL+9532

OIL UNIT

500

75t MOBILE CRANE (SUPPLIED BY OWNER) 650 1700

3550

B3 B4

A3 A4

UP

B5

UP

ROTOR 31.5ton

)

1170

RAIN COVER

D.N

UP

C1

C2

D1

D2

R 65 0 W (c ap ork rad 0 ac ity ius 3 9.4 ton)

1600 650 1450 900 890

GL+9532

MONORAIL FOR REAR CASING BOS GL+13700 (I-450x175)

D.N

C3

C4

D3

D4

PLAN

10400

12850

1050

MOTORIZED HOIST 20ton GL+15285 MSL+19785 min. 1890

GL+13700 MSL+18200 GL+12200 MSL+16700

REAR CASING 3.6ton

GL+9500 MSL+14000

5310

A2

A3

A1

2000

RAIN COVER

GL+4500 MSL+9000

A4 OIL UNIT

Rev.003

CARRIER (SUPPLIED BY OWNER) 5200 7020

7050

3. OVERHAUL PROCEDURE REAR CASING (REF. TO SECTION A-A & B-B) 1) LIFT UP THE REAR CASING FROM THE POSITION A1 TO A2 WITH MOTORIZED HOIST 2) MOVE THE REAR CASING FROM THE POSITION A2 TO A3 AND TURN IT. 3) PUT DOWN THE REAR CASING ON THE CARRIER FROM THE POSITION A3 TO A4 . 4) MOVE THE REAR CASING FROM THE POSITION A5 TO TEMPORARY STORAGE AREA. 4. PARTS WEIGHT IMPELLER CASING REAR CASING ROTOR

: 12.0ton : 3.6ton : 31.5ton

AIR HOUSING MOTOR

: 3.4ton : 38.1ton

GL+9532

MONORAIL

890

4200

GL+12200

ELECTROSTATIC PRECIPITATOR 3A

650

450

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

1700

1050

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

900 1050

900 1450 650 1600

2000

GL+12200

NOTES :

FLOOR(GL+12200)

450

4200

GL+9532

FLOOR(GL+12200)

1050 900

ELECTROSTATIC PRECIPITATOR 3A

A

B

40t TRAILER (SUPPLIED BY OWNER) MONORAIL FOR REAR CASING BOS GL+13700 (I-450x175)

GL+9532

500

AIR HOUSING 3.4ton

15t TRUCK (SUPPLIED BY OWNER)

RAIN COVER

ELECTROSTATIC PRECIPITATOR 3A

ELECTROSTATIC PRECIPITATOR 3B

A'

B'

ELECTROSTATIC PRECIPITATOR 3B

MONORAIL FOR IMPELLER CASING & ROTOR BOS GL+13700(I-600x190)

B'

FGD/EP/ ASH HANDLING SYSTEM CONT. & ELEC. BUILDING 7050 (c R6 a 5 W pac 00 o r it y k ra 3 9 di .4 us to n

Disassembly and Reassembly

5. REFERENCE DWG. No. G101-31-3-05-00-E001 (97000-2001) PLOT PLAN

5200 10400

MM-M02.02

SECTION A-A OVERHAUL OF REAR CASING

FIGURE 5-1A Induced Draft Fan Mitsubishi

IDF OVERHAUL PLAN – 1/2

5-15

Chapter 5

Disassembly and Reassembly

NOTES :

MOTORIZED HOIST 37.5ton

IMPELLER CASING 12.0ton 5050

B2

B3

B1

GL+15285 MSL+19785

GL+13700 MSL+18200 GL+12200 MSL+16700

GL+13700 MSL+18200 GL+12200 MSL+16700

min. 2150

GL+15285 MSL+19785

ROTOR 31.5ton

RAIN COVER

GL+9500 MSL+14000

C3

2000

RAIN COVER

MOTORIZED HOIST 37.5ton

C2

TEMPORARY RACK (SUPPLIED BY OWNER)

GL+4500 MSL+9000

C1

B4

7050

5200

5200

10400

7020

7050

SECTION A'-A'

OVERHAUL OF IMPELLER CASING

OVERHAUL OF ROTOR

2010

1700

1700

2010

AIR HOUSING (REF. TO SECTION B-B) 1) LIFT UP THE AIR HOUSING FROM THE POSITION D1 TO D2 WITH MOBILE CRANE. 2) MOVE THE AIR HOUSING FROM THE POSITION D2 TO D3 AND TURN IT. 3) PUT DOWN THE AIR HOUSING ON THE TRUCK FROM THE POSITION D3 TO D4 .

5200 10400

SECTION A-A

2840

(REF. TO SECTION B-B) MOTOR 1) LIFT UP THE MOTOR FROM THE POSITION POSITION E1 TO E2 WITH MOBILE CRANE. 2) MOVE THE MOTOR FROM THE POSITION E2 TO E3 . 3) PUT DOWN THE MOTOR ON THE TRAILER FROM THE POSITION E3 TO E4 .

2840

MOTORIZED HOIST 37.5ton

4. PARTS WEIGHT IMPELLER CASING : 12ton : 3.6ton REAR CASING : 31.5ton ROTOR : 3.4ton AIR HOUSING : 38.1ton MOTOR

MOTORIZED HOIST 37.5ton GL+15285 MSL+19785

GL+15285 MSL+19785 GL+13700 MSL+18200

5. REFERENCE DWG. No. G101-31-3-05-00-E001 (97000-2001) PLOT PLAN

GL+13700 MSL+18200 GL+12500 MSL+17000

MOTORIZED HOIST 20ton

IMPELLER CASING 12.0ton

MOTORIZED HOIST 20ton

12

B2

REAR CASING 3.6ton

A2

AIR HOUSING 3.4ton

ROTOR 31.5ton

OM BO

m

MOTOR 38.1ton

m 12

BO OM

GL+12500 MSL+17000

C2

3550 1170

2000

A1

B1 E1

C1 GL+4500 MSL+9000

D1

GL+4500 MSL+9000

3000

3000 6550

6550

8800

75t MOBILE CRANE (SUPPLIED BY OWNER)

D2

E2

Rev.003

ROTOR (REF. TO SECTION A-A) 1) LIFT UP THE ROTOR FROM THE POSITION POSITION C1 TO C2 WITH MOTORIZED HOIST 2) MOVE THE ROTOR FROM THE POSITION C2 TO C3 . 3) PUT DOWN THE ROTOR ON THE TRAILER FROM THE POSITION C3 TO C4 .

40t TRAILER (SUPPLIED BY OWNER) 5200

MM-M02.02

GL+4500 MSL+9000

OIL UNIT

CARRIER (SUPPLIED BY OWNER)

75t MOBILE CRANE (SUPPLIED BY OWNER)

3. OVERHAUL PROCEDURE IMPELLER CASING (REF. TO SECTION A-A) 1) LIFT UP THE IMPELLER CASING FROM THE POSITION B1 TO B2 WITH MOTORIZED HOIST 2) MOVE THE IMPELLER CASING FROM THE POSITION B2 TO B3 AND TURN IT. 3) PUT DOWN THE IMPELLER CASING ON THE CARRIER FROM THE POSITION B3 TO B4 . 4) MOVE THE IMPELLER CASING FROM THE POSITION B5 TO TEMPORARY STORAGE AREA.

C4 OIL UNIT

7020

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

GL+9500 MSL+14000

5050

min. 2150

MONORAIL

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

ELECTROSTATIC PRECIPITATOR 3B

2000

ELECTROSTATIC PRECIPITATOR 3A

8800

6550

3550 6550

SECTION B-B

SECTION B'-B'

OVERHAUL OF MOTOR

OVERHAUL OF MOTOR COOLER

1170

FIGURE 5-1B Induced Draft Fan Mitsubishi

IDF OVERHAUL PLAN – 2/2

5-16

Chapter 5

5.2

Disassembly and Reassembly

Rotor Disassembly and Reassembly a)

Preparation If disassembly of the moving blades and the hydraulic cylinder in IDF 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 work. 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. 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 any inspection / maintenance.

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

CAUTION After completing maintenance in the oil lines of the bearing box / oil unit, do a complete oil flushing.

MM-M02.02

Rev.003

b)

Disassembly All data is to be recorded during the disassembly of each part. During disassembly, make match marks on adjoining parts for reference during the reassembly. The disassembly procedure is described as follows after removing the ID fan impeller and rear casing assembly as detailed in section 5.1.

Induced Draft Fan Mitsubishi

5-17

Chapter 5

Disassembly and Reassembly

Disassembly of Moving Blades and Moving Blade shafts Before the disassembly of the servo cylinder and piston, the disassembly of moving blades and blade shafts can be done sequentially. Refer to Figures 2-6 and 5-3. 1

Remove the blot (29) and remove the side plate (12), (52).

2

Support the moving blade by using chain block.

Note Remember to match mark the blades and their installed locations before starting the disassembly of moving blades.

Note When removing the blade, to prevent rotor rotation due to unbalance, fix the rotor using chain blocks and remove the blades in a balanced manner.

3

Remove the set screws (38) and the U-nut (37) and then unscrew the nut for M/B shaft (13) by using special tool (spanner) and place it down inside the rotor.

4

Take care that the M/B support bearing (56) does not fall down while removing the nut for M/B shaft (13).

5

Lightly tap and remove the moving and M/B support bearing (56) and place it inside the rotor along with the nut for M/B shaft (13).

6

Slowly pull the moving blade (1) & M/B shaft (7) outwards from the rotor disk (9&10) handling the M/B support bearing (56), nut for M/B shaft (13) and spacer (50) carefully.

7

Remove the M/B support bearing (56) and the nut for M/B shaft (13) and spacer (50).

8

Above removing the moving blades and M/B shafts ( item 3 ~ 7) is carried out in the following sequence

Rev.003

Mark the blades 1 to 16, position the shaft such that blade Nos. 1 and 2 are located at the topmost elevation and then remove the blade Nos. 1 and 2.

(ii) Rotate the rotor by 180° such that blade Nos. 1 and 2 are located at the bottom side and blade Nos. 9 and 10 at the top side and then remove the blade Nos. 9 and 10.

MM-M02.02

(i)

(iii) Rotate the rotor by 90° such that blade Nos. 13 and 14 are located at the top side, then lock the rotor and remove the blade Nos. 13 and 14. Induced Draft Fan Mitsubishi

5-18

Chapter 5

Disassembly and Reassembly

(iv) Rotate the rotor by 180° such that blade Nos. 5 and 6 are located at the top side, then lock the rotor and remove the blade Nos. 5 and 6. (v) Rotate the rotor by 90° such that blade Nos. 15 and 16 are located at the top side, then lock the rotor and remove the blade Nos. 15 and 16. (vi) Remove blade Nos.7 and 8. (vii) Remove blade Nos.11 and 12. (viii) Remove blade No. 3 and 4. 9

Remove the blade fixing bolts (32) and separate moving blade and M/B shaft if needed. Usually moving blade and M/B shaft are not disassembled.

Disassembly of Servo Cylinder and Piston Refer to Figure 2-7 and 5-2. 1

Remove the bolts (47), retaining ring (37) from the servo cylinder (1) nut (11) and remove the nut (11) and the MV packing (18).

2

Remove the bolts (12) and then remove the servo cylinder (1) together with the bush (44). Recover the O-rings (20 and 21).

3

Remove the bush (44) from the cylinder cover (2) after removing screw (46).

4

Unfold the lock washer (19) and unscrew the nut (6) from the rotor.

5

Remove the piston (5) from the rotor by using special tools (draw out tool, bolt & nut). Recover the pin (28).

6

Remove the piston rings (13) from the piston.

7

Remove the bolts (48), retaining ring (49) from the cylinder cover (2) and remove the nut (10) and the MV packing (17).

8

Remove the pin (29) and withdraw the pilot sleeve carefully by using special tools (draw out tool, guide bar & nut and bolt) and recover O-rings (38 & 39).

Note The pilot sleeve shall be kept in the oil bath together Rev.003

with pilot valve.

Note

MM-M02.02

MHI recommends the replacement of the pilot valve (3) and the sleeve (4) every 6 years. (If there is spare, every 8 years).

Induced Draft Fan Mitsubishi

5-19

Chapter 5

Disassembly and Reassembly

Disassembly of the Crank Arm Following the disassembly of servo cylinder, the disassembly of crank arm can be done. Refer to Figures 2-6 and 5-3. 1

Remove the driving coupling (4) from DE side by removing bolts (33).

2

Remove the side ring of actuator disk (11) from the DE side of the rotor by removing the bolt (31).

3

Remove the crank arm (8) from it s position by removing the retaining ring (26) along with the sliding piece for crank arm (53). Separate the sliding piece for crank arm (53) from the crank arm (8) by removing the retaining ring (45).

Note Remove the torque limiter assembly by removing the lock nut and keep it safely. No disassembly of the mechanism is to be done at site. If found damaged, the same shall be replaced and the defective one shall be sent to MHI, Nagasaki for repairs.

Refer to Figure 2-6, 2-7, 5-2 and 5-3 4

Remove the cylinder cover (2 of Figure 2-7/5-2) with MV packings (17 of Figure 2-7/5-2) and the bush (45 of Figure 2-7/5-2) from NDE side by removing bolts (33 of Figure 5-3). Remove the bush on the cylinder cover, if necessary, by removing its fixing screws (46 of Figure 2-7/5-2).

5

Remove the side ring of actuator disk (11 of Figure 2-6/5-3) from NDE side of rotor by removing the bolt (31 of Figure 2-6/5-3).

6

Remove the crank arm (8 of Figure 2-6/5-3) from its position by removing the retaining ring (26 of Figure 2-6/5-3) along with the sliding piece for crank arm (53 of Figure 2-6/5-3). Separate the sliding piece from the arm by removing the retaining ring (45 of Figure 2-6/5-3.

Disassembly of the Regulating Disk and Shaft

After removal of the moving blades etc as discussed above proceed as follows to remove the regulating disk and shaft. 1

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Rev.003

Refer to Figures 2-6 and 5-3.

Induced Draft Fan Mitsubishi

Remove the regulating disk tighten nuts (17) and the washer (34&35) by using special tool (wrench).

5-20

Chapter 5

Disassembly and Reassembly

2

Using puller remove the operating disks (10) at end of the regulating shaft (3).

3

Remove the keys (20&21).

4

Remove screw (41) and the stopper plate (28) from both ends of the main shaft.

5

Pull out the regulating shaft (3) from the NDE side.

6

Remove the bush (25) from both ends of the main shaft inner side.

Note Sleeve replacement may involve machining.

Disassembly of Rotor Refer to Figures 2-6 and 5-3.

CAUTION When removing the rotor, take care of the proper supporting of the entire rotor and bearing box assembly. The rotors are to be gradually moved towards outside in a balanced manner.

1

Install two hydraulic jacks between the inner faces of the rotors (5&6) in the same horizontal plane that contains the shaft center line.

2

These hydraulic jacks are used to provide necessary thrust force to push the rotors outwards. Refer to Figure 5-4.

3

By using special tools (spanner, fitting plate, fitting piece, spacer, bolt and cylinder), partially unscrew the rotor tighten nuts (14&15) from the driven end and let it remain on the shaft.

4

Apply heat to the center bore of the 1st rotor through which the main shaft (2) passes the rotor. In normal operating temperature, the rotor bore diameter is slightly less than the main shaft (2) outer diameter. So, heating is required to expand the rotor bore diameter so that the rotor can be pushed out of the shaft.

Rotor Heating Procedure for disassembly: Rev.003

Note Disassembly and reassembly of the rotor / main shaft

MM-M02.02

shall be done during the Boiler outage, by applying heat to the rotor

Induced Draft Fan Mitsubishi

5-21

Chapter 5

Disassembly and Reassembly

CAUTION We recommend using a gas burner to heat the rotor rather than an oil bath. Burner flame must be wide to heat the rotor. Always use red flame of Propane gas, not the blue flame of Acetylene gas. To heat the rotor, move the flame uniformly over the rotor inner and outer surfaces. Do not heat until the paint is burnt or damaged. The following steps shall explain the rotor heating procedure. (i)

Two maintainers shall heat the rotor outer side (5), inside and outside.

(ii) Another two maintainers shall heat the bearing side of the rotor outer side. (iii) Target temperature of rotor surface is 100°C. (iv) When the rotor surface temperature reaches 100°C, one maintainer shall start heating the rotor outer side. At the same time, the second maintainer shall start heating the boss internal i.e. shaft fitting area. (v) Two maintainers who are heating the rotor on the bearing side, shall heat the boss part gradually. (vi) While heating, take extra care not to bend the rotor.

CAUTION If the rotor is bent, internal component cannot be disassembled.

5

Now apply hydraulic pressure to the rotors by means of the hydraulic jacks and slightly slide 1st rotor (5) outwardly (around 80 mm). But do not remove it from the shaft.

CAUTION

MM-M02.02

Rev.003

When removing the rotor, take care of the proper supporting of the entire rotor and bearing box assembly. The rotors are to be gradually moved towards outside in a balanced manner. 6

Tighten the rotor tighten nut (15).

7

Now repeat step 3 to 5 for 2nd rotor (6).

8

Remove the 2nd rotor using suitable lifting equipment and collect the key (19).

Induced Draft Fan Mitsubishi

5-22

Chapter 5

Disassembly and Reassembly

Note Take care of hydraulic jacks dropping down.

9

Remove the rotor tighten nut (15) and repeat step 8 for 1st rotor (5).

CAUTION When removing the rotors (5&6), take care of the proper supporting of the rotor and bearing box assembly if the IDF is maintained in the lay down area. The rotors are to be gradually moved towards outside in a balanced manner.

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 IDF. All used gaskets and O-rings are to be discarded and replaced with new ones.

Reassembly of Rotor Refer to Figures 2-6 and 5-3. 1

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

Rotor Heating Procedure for Reassembly:

Note •

Disassembly and reassembly of the rotor (5 & 6) / main shaft shall be done during the Boiler outage, by applying heat to the rotor.



To fix the main shaft, fill it with dry ice to reduce the temperature



For fixing the rotor, heat it around to extend the center bore diameter of the rotor

CAUTION Rev.003

We recommend using a gas burner to heat the rotor rather than an oil bath. Burner flame must be wide to heat the rotor.

MM-M02.02

Always use red flame of Propane gas, not the blue flame of Acetylene gas. To heat the rotor, move the flame uniformly over the rotor inner and outer surfaces. Induced Draft Fan Mitsubishi

5-23

Chapter 5

Disassembly and Reassembly

The following steps shall explain the rotor heating procedure. (i)

Two maintainers shall heat the 2nd rotor outer side (6), inside and outside.

(ii) Another two maintainers shall heat the bearing side of the rotor outer side (6). (iii) Target temperature of rotor surface is 100˚C.

CAUTION Do not heat until the paint is burnt or damaged.

(iv) When the rotor surface temperature reaches 100˚C, one maintainer shall start heating the rotor outer side. At the same time, the second maintainer shall start heating the boss internal i.e. shaft fitting area. (v) Two maintainers who are heating the rotor on the bearing side, shall heat the boss part gradually. (vi) While heating, take extra care not to bend the rotor (6).

CAUTION If the rotor is bent, internal component cannot be assembled.

(vii) If the extension of the rotor boss diameter is measured about 0.25 to 0.30mm against main shaft, the rotor and the shaft are ready to be assembled. (viii) Before inserting the rotor into the shaft, adjust the center lines of rotor boss and main shaft. (ix) Fix two chain blocks on right and left side of the heated rotor. (x) Pull the chain blocks and verify that the main shaft is slightly fitted into the bore of the rotor.

CAUTION

MM-M02.02

Rev.003

Do not pull the rotor excessively to cause any damage to the Main bearing. 1

Install the rotor disks over the respective shaft keys (19).

2

Install the 2nd rotor (6) and then the 1st rotor disk (5).

3

Fasten the rotor tighten nuts (14&15) by using special tools (spanner, fitting plate, fitting piece, spacer, bolt and cylinder).

Induced Draft Fan Mitsubishi

5-24

Chapter 5

Disassembly and Reassembly

Reassembly of Regulating Disk and Shaft Refer to Figures 2-6 and 5-3. 1

Apply oil/grease on the regulating shaft (3) and insert the operating shaft from the NDE side.

2

Locate the bushes (25) on both ends of the main shaft and set the stopper (41) with the machine screw (28).

3

Install the keys (20&21) on the DE and NDE ends of the regulating shaft (3).

4

Install the regulating disks (9) on the DE and NDE sides such that the disk buts the collar on the regulating shaft (3).

5

Locate the washer (34 & 35) and the regulating disk tighten nuts (14&15) on the DE and NDE ends of the regulating shaft and tighten them.

Reassembly of Crank Arm Refer to Figures 2-6 and 5-3. 1

Connect the sliding piece for the crank arm (53) to the crank arm (8) by fixing the retaining ring (45). Install the crank arm (8) in its marked position with the retaining ring (26) along with the sliding piece for crank arm (53). Insert the respective bushes (24)

2

Install the side ring of the actuator disk (11) on the DE side of the rotor by fixing the bolt (31).

3

Install the driving coupling (4) on DE side with bolts (33).

4

Install the removed torque limiter assembly (54) carefully.

5

Install the side ring of the actuator disk (11) on the NDE side of the rotor by fixing the bolt (31).

Reassembly of Servo Cylinder and Piston (including moving blade regulating mechanism)

1

Install the bush (45) on the cylinder cover (2) by its fixing screws (46).

2

Install the cylinder cover (2) on the operating shaft along with packings (17) and the bush (45) by bolts (33 of figure 5-3).

3

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)

MM-M02.02

Rev.003

Refer to Figures 2-7 and 5-2.

Induced Draft Fan Mitsubishi

5-25

Chapter 5

Disassembly and Reassembly

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

Note Additional details on MV-packing insertion are provided in Appendix H.

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

4

Install and gradually tighten the plate for MV packing (10) to the cylinder cover (2) by bolts (48).

5

Install the retaining ring (49) after final tightening of the plate for MV packing (10).

6

Insert the O-rings (38&39) on the pilot sleeve (4) and insert the pilot sleeve to the regulating shaft by using special tool.

7

Secure the pilot sleeve (4) with the straight pin (29).

8

Install the locating pin (28) and locate the piston (5) with piston rings (13) on the regulating shaft. Lock it in position by the nut for piston (6) and washer (19).

9

Install the bush (44) with screw (46) on the cylinder (1).

10 Install the O-rings (20&21) in position. 11 Insert the cylinder (1) onto the cylinder cover (2) by bolts (12). 12 Insert the MV packings (18) and assemble the nut (11) and bolt (47) and retaining ring (37). (Same as item 3~5) 13 Install the blade (16) on the pilot sleeve (4) with machine screw (26) and spring washer (30).

Rev.003

14 Install the scroll (14) with the retaining rings (34) and screw (27) and spring pin (33) on the pilot valve (3).

Note

MM-M02.02

Check stroke of pilot valve by manual operation by running the oil pump.

Induced Draft Fan Mitsubishi

5-26

Chapter 5

Disassembly and Reassembly

CAUTION Remove any spilled oil from the working area to avoid slippage.

CAUTION After any major inspection, do a complete oil flushing.

Reassembly of Moving Blades & Moving Blade Shaft Refer to Figures 2-6 and 5-3. 1

Install the bush (23) on the moving blade (1) and M/B shaft (7).

2

Slide the moving blade (1) and M/B shaft (7) through the hole on the rotor and simultaneously locate the M/B support bearing (56), cover (27), nut for M/B shaft (13) and spacer (50) from the inner side of the rotors (5&6) and insert the shaft bottom end on to the crank arm (8).

3

Tighten the nut for M/B shaft (13) by using special tool (spanner) and then lock it with U-nut (37) and set screw (38).

4

Complete the assembly of all shafts on both the rotors (5&6) following the same sequence for disassembly.

Note Control match marks of moving blades and shafts on the rotor disks (5&6). Apply lubricant to threads and seating surfaces when tightening bolts. Take care to locate the blade assemblies in their original position, as they were prior to disassembly

CAUTION

MM-M02.02

Rev.003

Do not use lubricants containing Molybdenum-Base such as Molycoat.

Induced Draft Fan Mitsubishi

5-27

Chapter 5

Disassembly and Reassembly

CAUTION If a moving blade is sticking after assembly, confirm the clearance and check for any crack. 5

Install side plate (12) on the rotor (5) by tightening bolts (29&30) as per the torque given in Appendix A. Ensure that the balance weights on the side plate are all in their original position.

6

Install side plate (52) on the rotor (6) by tightening bolts (29&30) as per the torque given in Appendix A. Ensure that the balance weights on the side plate are all in their original position.

7

Complete the assembly of all blades on both the rotors (5&6) following the same sequence as for disassembly.

8

Measure and record the moving blade radial clearance between the blade root and the rotor disk and ensure that the clearance is within tolerance as indicated in Figure 4-1.

9

Adjust the axial clearance of the moving blade.

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

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.

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

MM-M02.02

Rev.003

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

Induced Draft Fan Mitsubishi

5-28

Chapter 5

Disassembly and Reassembly

SURVO CYLINDER CYLINDER COVER

6 COVER JOINT 10

PLATE FOR MV PACKING PLATE FOR MV PACKING

SCROLL FLOATING RING

19 O RING 21 22 24

BOLT

STRAIGHT PIN

31 SPRING PIN

RETAINING RING 38

PLUG

44

MM-M02.02

Rev.003

21

FIGURE 5-2 Induced Draft Fan Mitsubishi 30

MOVING BLADE REGULATING MECHANISM EXPLODED VIEW

5-29

Chapter 5

Disassembly and Reassembly

60 1 32

56

MM-M02.02

Rev.003

38 37

FIGURE 5-3 Induced Draft Fan Mitsubishi

IDF ROTOR EXPLODED VIEW

5-30

Chapter 5

Disassembly and Reassembly

NON DRIVE END 2nd STAGE ROTOR

DRIVE END

HYDRAULIC JACK

1st STAGE ROTOR

BEARING BOX

KEY

NUT

MAIN SHAFT

NUT

HYDRAULIC JACK

A-A HYDRAULIC JACKS

I

ROTOR DISK

Rev.003

B-B

MM-M02.02

MPTD-4-0661

FIGURE 5-4 REMOVAL OF ROTOR DISKS

Induced Draft Fan Mitsubishi

5-31

Chapter 5

5.3

Disassembly and Reassembly

Bearing Disassembly and Reassembly a)

Preparation If bearing box 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 commencement of work. 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 disassembly work.



Prepare a suitable fixture to support the rotor assembly vertically for 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 casings during reassembly.

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

CAUTION

MM-M02.02

Rev.003

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

Induced Draft Fan Mitsubishi

5-32

Chapter 5

b)

Disassembly and Reassembly

Disassembly The disassembly of the bearing box can be carried out after the removal of rotor wheel as explained in Sections 5.1 and 5.2 as the bearing box is a single cylinder sandwiched between the two rotor disks. All data is to be recorded during disassembly of each part. During disassembly, make match marks on 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. Care is to be taken to protect the machined surfaces.

Refer to the Figures 5-5 and 5-6. 1

Clean the area around the bearing box before disassembly to prevent foreign material from entering the bearing.

2

Drain the oil from the bearing box into a suitable container by removing the drain pipe cover flange.

Note Take care of damage of the pipe for oil return in transporting.

Note Bearings removed from the shaft shall not be reused..

3

Remove the bolt (24) and washer (29) and then remove the bearing box covers (36 &37) with O ring (16), labyrinth ring (50), seal ring (19) and O ring (41) from both ends of the shaft.

Rev.003

Note Take care of foreign material not entering the bearing.

MM-M02.02

4

Induced Draft Fan Mitsubishi

Remove adjustable ring (2) from the bearing box by removing the threaded pin (3) and then the O- ring (17).

5-33

Chapter 5

Disassembly and Reassembly

5

Remove the sleeves (49).

6

Remove the inspection hole cover (38) and the lube oil strainers (39) and clean the oil strainers.

7

Using suitable chain pulley/block hoist place the bearing and the shaft assembly in the vertical orientation over a support such that the non-drive end remains at the top. Refer to Figure 5-6.

Note Take care of the dropping of the outer surface of drive-end bearing.

8

Using suitable lifting equipment, lift the shaft assembly as shown in Figure 5-6 from inside of the bearing box.

9

The complete NDE bearing assembly (43&44) and inner race of the DE bearing (42) shall be lifted during above operation.

Note MHI recommends to replace the seal ring (19) O-rings (16~18, 20~22, 41) and Packing (6~8) on every overhaul. Bearings are to be changed during every 4 yearly overhauls. (If there is spare every 8 years.)

CAUTION Special care is to be taken to prevent the outer race of radial bearing and the bush from falling. Transport the shaft to the lay down area and fix it.

11

Remove the outer race of NDE roller bearings (43) from the non-drive end of the rotor. Remove the oil distributor ring (48) between the roller bearing and ball bearing. The inner race and outer race are provided with 2 tapped holes (M12) for handling purpose. Use suitable lifting bolts.

12

In order to remove the shrunk fit inner races of the bearings, install the dry ice into the main shaft. After enough cooling, apply heat to the inner races of the bearing at drive and non drive end. Add any additional force required to remove the inner races.

13

Remove the inner race of the roller bearing on DE side.

14

Remove the inner race of the roller bearing and ball bearings at the non drive end along with the spacers. Carefully pull out the assembly such that the loose bearing spacers (45&46) and oil distributor ring (47&48) do not fall and get damaged.

15

Remove bush (40) and O-rings (18) on the NDE side.

MM-M02.02

Rev.003

10

Induced Draft Fan Mitsubishi

5-34

Chapter 5

c)

Disassembly and Reassembly

16

Rotate the bearing box and put it in the DE side up position. Then remove the outer race with rollers of drive end bearing (42).

17

Remove bush (40) and O-rings (18) on the DE side.

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 IDF. The used gaskets and O-rings are to be discarded and replaced with new ones. Refer to Figures 5-5 & 5-6. 1

Clean the bearing seating surfaces on the rotor. Minor surface corrections shall be carried out using an oil stone.

Note The reassembly of the bearings and the coupling hub on the rotor to be carried out in the vertical position as indicated in Figure 5-6. Only new bearings shall be assembled.

2

Locate the O-rings (18) and bush (40) and restore the radial bearing outer race with rollers inside the DE of the bearing box and put the bearing box in the NDE side up position on the temporary support.

3

Locate the O-rings and bush (40) on the NDE side.

4

Heat the inner race of the DE radial bearing (42) in an oil bath to about 100°C until the inner race diameter increases by more than 0.1 mm.

5

Transfer the inner race of radial bearing (42) from the oil bath or oven and install it on the rotor so that the inner race abuts the step provided on the rotor. 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.

6

Following the heating procedure explained in Step 4, heat the NDE first ball bearing (44) and insert it onto the rotor so that it abuts firmly onto the step provided on the rotor.

Note Allocation of bearings is referred to the match marks made on their outer surface.

7

MM-M02.02

Rev.003

Take care to install the bearings as per their direction.

Induced Draft Fan Mitsubishi

Cool down to ambient temperature and next install the spacer (45) and oil distributor (47).

5-35

Chapter 5

Disassembly and Reassembly

8

Following step7 install the 2nd ball bearing (44). Install the bearing spacer (46) and oil distributor ring (48) and finally the NDE roller bearing (43).

9

Install the O-ring (17) in the slot on the inner surface of bearing box.

10 Install the O-ring (41) in the slot on the inner surface of the sleeves (49) and then install the sleeves onto the rotor ends. 11 Transport the rotor shaft assembly and return it into the bearing box through the NDE side.

Note Ensure that all the bearings (42, 43&44), oil distributor ring, bushes around the radial bearings seat properly in their respective locations

12 After checking for cleanliness, place the bearing box and shaft assembly in a horizontal position onto the main support structure prepared for rotor wheel disassembly. 13 Install the seal rings (19), adjustable rings (2) and the O-rings (16, 17, 20~22) at the bearing box covers (36&37) and tighten the bearing box covers (36&37) with the fixing bolts and washers (24&29).

Note Check and adjust the labyrinth seal clearance according to the value specified in Figure 4-1.

14 Clean the lube oil strainers (39) and the inspection hole cover (38) on the bearing box.

CAUTION Take care that there is no foreign matter in the lubricating oil line. Lubricating holes for strainers, bearing box cover lubricating oil lines are very small. When assembling, make sure that the lubricating holes are not blocked.

Rev.003

CAUTION

MM-M02.02

After maintenance in the oil lines of the bearing box / oil unit, arrange oil flushing.

Induced Draft Fan Mitsubishi

5-36

Chapter 5

Disassembly and Reassembly

3

34 50

1

28 9

Rev.003

24 25

MM-M02.02

7

MPTD-3-0074

Induced Draft Fan Mitsubishi

FIGURE 5-5

BEARING BOX EXPLODED VIEW

5-37

Chapter 5

Disassembly and Reassembly

ITEM

46 43

48

44 47 45

NON DRIVE END

BEARING BOX

40

BUSH

42

DE BEARING (ROLLER)

43

NDE BEARING (ROLLER)

44

NDE BEARING SET (BALL)

45

BEARING SPACER 1

46

BEARING SPACER 2

47

OIL DISTRIBUTOR RING 1

48

OIL DISTRIBUTOR RING 2

51

MAIN SHAFT

51

42

DRIVE END

DESCRIPTION

1

INNER RACE

40

1

40

42

OUTER RACE

MM-M02.02

Rev.003

TEMPORARY SUPPORT (SHOP FABRICATED)

MPTD-4-0660

FIGURE 5-6 Induced Draft Fan Mitsubishi

REMOVAL OF ROTOR SHAFT FROM BEARING BOX

5-38

Chapter 5

5.4

Disassembly and Reassembly

Linkage Mechanism 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 commencement of work. 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 item does not fall on the impeller wheel assembly.

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

MM-M02.02

Rev.003

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

Induced Draft Fan Mitsubishi

5-39

Chapter 5

b)

Disassembly and Reassembly

Disassembly All data is to be recorded during the disassembly of each part. During disassembly, make match marks on adjoining parts for reference during the reassembly. The disassembly procedure is described as follows: Refer to Figures 2-8 and 5-7. 1

Remove the split pins (20&42), pins (5), bolts (40) and nuts (12&41), thus disconnecting the linkage assembly both from the pilot valve end and the control drive. 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 (10) on the stand for drive unit (34). Similarly if detective cylinder assembly (29) is to be removed loosen and remove the bolts (38&39). For disassembly and reassembly of the control drive unit and detective cylinder assembly please refer to the respective I&C vendor manual.

2

Remove the taper pin (22&23), U-nuts (26&27) and set screws (18&28).

3

Remove the set screw (19).

4

Remove the levers (32&33) from the operating shaft (30) and remove the piece (4).

5

Remove the spring pin (24) and the scale pointer (31).

7

Remove the bolts (9), washers (13) and nuts (14), loosen set screws (36&46). Remove the dust protect cover (37).

8

Remove the ball bearing units (7&8) secured to the operating shaft support (45).

9

Remove the taper pin (21), bolts (11) and washers (16).

10 Remove the stand for scale plate (2) together with scale plate (3) from the operating shaft support (45).

MM-M02.02

Rev.003

11 Withdraw the operating shaft (30) axially from outside the rear casing (43).

Induced Draft Fan Mitsubishi

5-40

Chapter 5

c)

Disassembly and Reassembly

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. Refer to Figure 5-7. 1

Clean the operating shaft (30) and insert it through the operating shaft support (45).

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 (45) flange with taper pin (21).

4

Secure it by bolts (11) and washers (16) from outside the rear casing (43).

5

Pack the ball bearing units (7&8) at both ends with lubricating grease and insert it through the operating shaft (30) from inside the rear inner casing.

6

Secure the ball bearing units (7&8) to the operating shaft support (45) flange with bolts (9), washers (13), (14).

7

Secure the operating shaft (30) on operating shaft support against rear inner casing and secure it with set screw (36 and 46).

8

Install the dust protective cover (37).

9

Install the scale pointer (31) and secure it to the operating shaft by the spring pin (24).

10 Insert the piece (4) then insert the lever (32) onto the operating shaft (30) from inside the rear inner casing. 11 Install the taper pin (22) and the U-nut (26). 12 Set the lever (32) in line with the pilot valve axis.

MM-M02.02

Rev.003

13 Install and tighten the set screws (18 and 19) 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 (12) on both ends of the lever. 16 Insert the split pins (20). Induced Draft Fan Mitsubishi

5-41

Chapter 5

Disassembly and Reassembly

17 Insert the lever (33) onto the operating shaft (30) from outside the rear housing. 18 Install the taper pin (23) and the U-nut (27). 19 Set the lever (33) in line with the actuator lever axis. 20 Install and tighten the set screw (28) after finalizing the lever position. 21 Connect the lever (33) to the actuator linkage assembly by installing the bolt (40), nut (41) and split pin (42). 22 Ensure that the direction of the blade sticking detector (29) as shown in Figure 5-7 before connecting the lever (33). 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 (33) and/or the blade sticking detector linkage assembly to achieve the full range of blade operation. 25 Loosen the spring pin (24) and adjust the pointer (31) to match the blade position of 0% to 100%.

MM-M02.02

Rev.003

26 Tighten the spring pin after final adjustment.

Induced Draft Fan Mitsubishi

5-42

Chapter 5

ITEM 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20

30

21 22 23

DESCRIPTION LEVER STAND FOR SCALE PLATE SCALE PLATE PIECE PIN SPHERICAL BEARING BALL BEARING UNIT BALL BEARING UNIT BOLT BOLT SOCKET HEAD BOLT NUT WASHER SPRING WASHER SPRING WASHER WASHER SCREW SET SCREW SET SCREW SPLIT PIN TAPER PIN THREAD END TAPER PIN THREAD END TAPER PIN

Disassembly and Reassembly

ITEM

DESCRIPTION

24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46

SPRING PIN WASHER U-NUT U-NUT SET SCREW DETECTIVE CYLINDER ASS'Y OPERATING SHAFT POINTER LEVER LEVER STAND FOR DRIVE UNIT HAWK ANCHOR BOLT SET SCREW DUST PROTECT COVER BOLT BOLT BOLT NUT SPLIT PIN REAR CASING REAR INNER CASING OPERATING SHAFT SUPPORT SET SCREW

45

8 46

MM-M02.02

Rev.003

4

MPTD-3-0073 MPTD-3-0386

FIGURE 5-7 Induced Draft Fan Mitsubishi

MB LINKAGE ASSEMBLY EXPLODED VIEW

5-43

Chapter 5

5.5

Disassembly and Reassembly

Coupling Disassembly and Reassembly a)

Preparation If IDF 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 commencement of work. 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 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 disassembly of each part. During disassembly, make match marks on adjoining parts for reference during reassembly. The disassembly procedure is described as follows: Refer to Figure 2-5 and proceed as follows. 1

Thoroughly clean the surrounding area and the suction casing (50) before commencement of work.

Refer to Figure 2-11 and proceed further as follows: 2

Support the spacer (3 of Figure 2-11) suitably by using special tools (supporting tool, joint bar ass’y and bolt & nut). (Refer to Figure 5-8)

3

Remove the coupling bolts (8) and U-nuts (9) from the coupling flange at the non-drive end (fan side) securing the hub (2) and the spacer (3).

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

4

Gently tap and remove the overload washers (7) from the coupling except from the hole where the coupling bolt has not been removed.

5

Gently tap and rotate the element (4) with respect to the remaining coupling bolt.

6

Support the spacer (3) suitably and remove the last coupling bolt (8) and nut (9) from the coupling between the spacer (3) and the hub (1). Remove the washers (5) and bushes (6) provided on this coupling bolt.

MM-M02.02

Rev.003

removal the element and the washers.

Induced Draft Fan Mitsubishi

5-44

Chapter 5

c)

Disassembly and Reassembly

7

Support the hub (2) and remove all the reamer bolts and nuts securing the hub (2) to the fan rotor coupling flange and remove the spacer (2) by using chain block.

8

If further disassembly is required, i.e. removal of motor coupling hubs, proceed as follows:

9

Provide a hub removal tool and withdraw the hub from the shaft.

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. Refer to Figure 2-11 and proceed further as follows. 1

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

2

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

3

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

4

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

5

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.

6

Ensure that the coupling spacer (3) is supported in the casing by special tools.

7

Install and secure the hub (2) to the driving coupling (Figure 2-6, (4)) with the reamer bolts (39) and nuts (40).

8

Check coupling alignment as indicated in Appendix D.

9

When satisfactory alignment has been achieved, install the overload washers (7), element (4), washers (5) and bushes (6), coupling bolts (8) and U-nuts (9).

MM-M02.02

Rev.003

10 Grease the faces between the element (4), washers (5) and bushes (6). Then tighten the reamer bolts to the torque specified in Appendix A. Refer to Figure 2-5. 11 Remove the tools and tackles from inside the suction casing (50). 12 Restore the suction inner casing (55) and coupling cover ass’y (58).

Induced Draft Fan Mitsubishi

5-45

Chapter 5

Disassembly and Reassembly

A

COUPLING PROTECTION CYLINDER

B

MOTOR SIDE

F.F. COUPLING

HUB (FAN SIDE)

CL OF FAN

5 3

4

2

1

5 3

4 1 2

B

A 9

10

6

8

B-B

Rev.003 MM-M02.02

FIGURE 5-8 Induced Draft Fan Mitsubishi

7 A-A

ITEM

MPTD-4-1216

7

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

SUPPORTING TOOL FOR FORM FLEX COUPLING SPACER

5-46

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 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 IDF 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.

MM-M02.02

Rev.003

c)

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

d)

Safety Precautions Refer to Section 4.1.4, Safety Precautions.

Induced 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-M02.02

Rev.003

This section provides information about carrying out troubleshooting and servicing for the IDF, 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.

Induced Draft Fan Mitsubishi

6-2

Chapter-6

TABLE 6-1 Fault Vibration

TROUBLESHOOTING – IDF

Possible Cause

Remedy

Lubricating oil supply flow/pressure low

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

Bearing clearance is outside criteria

Check and replace

Bearing damaged

Replace bearings

Unbalance of rotor wheel and rotor shaft due to excessive wear

Perform field balancing

Bearing fixing bolts loose

Tighten fixing bolts

Coupling deformation

Replace the damaged coupling components and realign 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

Inadequate sealing/cooling air

Clean suction filter and readjust seal air control damper opening

Foreign material inside the fan casing/duct

Check and remove as necessary.

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

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 the pilot valve to obtain the 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

Control/lubricating oil pressure low

MM-M02.02

Rev.003

Corrective Maintenance

Induced 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 TABLE 7-1

RECOMMENDED LUBRICATION FOR IDF

MM-M02.02

Rev.003

TABLE 7-1 RECOMMENDED LUBRICATION FOR IDF

Induced Draft Fan Mitsubishi

7-1

Appendix A

A p p en d i x

A Torque Chart TABLE A-1 TORQUE CHART Description

Size

Quantity

Securing bolt for moving blade

M32

192

992 Nm

-

Reamer bolt and nut (for Flex coupling)

M52

20

4020 Nm

-

Reamer bolt and nut (driving coupling and Flex coupling)

M42

8

1667 Nm

-

Bolt for drive coupling

M30

56

981Nm

-

Bolt (for operating disc)

M30

48

981Nm

-

Bolt (side plate)

M30

32

981Nm

U nut (for m/b shaft)

M10

32

21 Nm

-

Bolt (for hub and spacer)

M36

6

1667 Nm

-

Fastening nut for rotor disc

M36

2

1666 Nm

Fastening nut for operating shaft-DE side

M36

1

1666 Nm

Fastening nut for operating shaft-NDE side

M300

1

73550 Nm

Remarks

1

Apply anti-seize compound to bolts.

2

Tighten the diametrically opposite bolts in sequence at Initial Torque - first outer periphery and then inner periphery.

3

Loosen the bolts.

4

Tighten the diametrically opposite bolts in sequence at 80%Torque - first outer periphery and then inner periphery.

5

Tighten the diametrically opposite bolts in sequence at 100% Torque - first outer periphery and then inner periphery.

Rev.003

Perform the following steps in sequence:

6

Again tighten the diametrically opposite bolts of outer periphery at 100% Torque.

MM-M02.02

Note:

Torque

7

Perform caulking.

Induced Draft Fan Mitsubishi

A-1

Appendix B

A p p en d i x

MM-M02.02

Rev.003

B Spare Parts

Induced Draft Fan Mitsubishi

B-1

Appendix B

MM-M02.02

Rev.003

TABLE B-1

RECOMMENDED STRATEGIC SPARE PARTS (OFF SHORE) Installed Qty.

Eqt. Description

Man. Parts No. (Note 2)

Eqt. Supplier Parts. ID. No.

Per each Eqt.

MOVING BLADE SUPPORT BRG.

IDF

-

LATER

2

PILOT VALVE AND SLEEVE

IDF

-

03HNCO1 AN1

3

MAIN BEARING ASSEMBLY

IDF

MHINGA

03HNCO1 AN1

4

SLIDING PIECE SLEEVE

MHINGA

03HNCO1 AN1

5

MHINGA

03HNCO1 AN1

MHINGA

On Hand Qty.

Total Qty.

Spare Parts (1yr) Opn

Strategic Spare

Expected Frequency of Replacement Months

32

64

-

64

48

36

J-TEXT

LATER

1

2

-

2

72

4

MHI-NGA

-

LATER

1

2

-

2

48

36

J-TEXT

IDF

-

LATER

32

64

-

64

48

3

MHI-NGA

OILESS BUSH FOR SLIDING PIECE

IDF

-

LATER

32

64

-

64

48

3

MHI-NGA

6

BUSH FOR MOVING BLADE SHAFT

IDF

-

LATER

32

64

-

64

48

2

MHI-NGA

03HNCO1 AN1

7

PISTON RING

IDF

-

LATER

1

2

-

2

48

4

MHI-NGA

MHINGA

03HNCO1 AN1

8

MV PACKING

IDF

-

LATER

1

2

-

2

48

1

MHI-NGA

MHINGA

03HNCO1 AN1

9

FLOATING RING FOR PILOT VALVE

IDF

-

LATER

1

2

-

2

48

1

MHI-NGA

MHINGA

03HNCO1 AN1

10

BUSH FOR CYLINDER ASSEMBLY

IDF

-

LATER

1

2

-

2

24

2

MHI-NGA

MHINGA

03HNCO1 AN1

11

NUT FOR PISTON

IDF

-

LATER

1

2

-

2

48

1

MHI-NGA

Supplier Name

Eqt. ID (Note 1)

Parts ID

MHINGA

03HNCO1 AN1

1

MHINGA

03HNCO1 AN1

MHINGA

Parts Description

Lead Time (Month) Receipt of PO - FOB

Name of Manufacture (Note 3)

Remark

Note1 : Equipment ID No. will be allocated by the buyer for each Project Equipment ID i.e. represents a unique ID No. of the Spare Parts. Note2 : Where the manufacturers drawings and parts nos is to be provided by the project, such number shall be indicated. If not the equipment supplier shall indicate its own no. such as catalogue no., product no., Type no. etc, for easy reference. Note3: If the equipmment supplier recommends The Buyer/Owner purchase the spare parts from the manufacturer, the name of the manufacturer, shall be indicated. Note4: In accordance with the commercial terms and conditions agreed in purchase order. Note5: Price should be valid for a period of minimum for 6 months. Note6: MPIM-8-8-1 MHI document Note7: Status is categorized into ordered, to be ordered, back ordered and received.

Induced Draft Fan Mitsubishi

B-2

Appendix B

CONTINUED FROM PREVIOUS PAGE

MM-M02.02

Rev.003

TABLE B-1

RECOMMENDED STRATEGIC SPARE PARTS (OFF SHORE) Installed Qty.

Eqt. Description

Man. Parts No. (Note 2)

Eqt. Supplier Parts. ID. No.

Per each Eqt.

FLEXIBLE HOSE SET

IDF

-

LATER

13

MANHOLE PACKING

IDF

-

03HNCO1 AN1

14

LINE STRAINER

IDF

MHINGA

03HNCO1 AN1

15

BAND FOR CASING

MHINGA

03HNCO1 AN1

16

MHINGA

03HNCO1 AN1

MHINGA MHINGA

Supplier Name

Eqt. ID Note 1

Parts ID

MHINGA

03HNCO1 AN1

12

MHINGA

03HNCO1 AN1

MHINGA

On Hand Qty.

Expected Frequency of Replacement Months

Lead Time (Month) Receipt of PO - FOB

Name of Manufacture

Total Qty.

Spare Parts (1yr) Opn

Strategic Spare

1

2

-

2

LATER

1

2

-

2

-

-

LATER

1

2

-

2

-

3

MHI-NGA

IDF

-

LATER

1

2

-

2

120

3

MHI-NGA

MOVING BLADE

IDF

-

LATER

32

64

-

64

120

10

MHI-NGA

17

DISK PACK FOR FF COUPLING

IDF

-

LATER

1

2

-

2

48

3

MHI-NGA

03HNCO1 AN1

18

V RING

IDF

-

LATER

2

4

-

4

48

1

MHI-NGA

03HNCO1 AN1

19

BUSH FOR OPERATING SHAFT

IDF

-

LATER

2

4

-

4

48

2

MHI-NGA

Parts Description

Remark

MHI-NGA MHI-NGA

Note1 : Equipment ID No. will be allocated by the buyer for each Project Equipment ID i.e. represents a unique ID No. of the Spare Parts. Note2 : Where the manufacturers drawings and parts nos is to be provided by the project, such number shall be indicated. If not the equipment supplier shall indicate its own no. such as catalogue no., product no., Type no. etc, for easy reference. Note3: If the equipmment supplier recommends The Buyer/Owner purchase the spare parts from the manufacturer, the name of the manufacturer, shall be indicated. Note4: In accordance with the commercial terms and conditions agreed in purchase order. Note5: Price should be valid for a period of minimum for 6 months. Note6: MPIM-8-8-1 MHI document Note7: Status is categorized into ordered, to be ordered, back ordered and received.

Induced Draft Fan Mitsubishi

B-3

Appendix C

A p p en d i x

MM-M02.02

Rev.003

C Special Tools

Induced Draft Fan Mitsubishi

C-1

Appendix C

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

PJ No.

T

RG

34

03HNC0 1AN1

Tool ID

1-1

Special Tool Name/ Description

SUPPORTING TOOL

Name of Equipment for which special tools used

IDF

Suppliers ID No. (Note 2)

B07200-0002-001001

IDF SPECIAL TOOL LIST (1 OF 8)

Total Qty. Supplied for Plant

2 SET

Purpose

FOR FF COUPLING

Ref. Instruction / Doc/Dwgs(Note # 3)

N29-10M-7096

Outline view & Dimensions (Note # 4)

Weight

24.3 kg

Remarks ASSEMBLING PARTS - ADJUSTING BOLTS: M30x1.5 (2PC) - NUT: M30x1.5 (2PC) SPECIAL TOOLS SHALL BE USED UNDER MHI SUPERVISION

T

RG

35

03HNC0 1AN1

1-2

SUPPORTING TOOL

IDF

B07200-0002-001002

2 SET

FOR FF COUPLING

N29-10M-7096

12.0 kg

ASSEMBLING PARTS - ADJUSTING BOLTS: M30x1.5 (1PC) - NUT: M30x1.5 (1PC) SPECIAL TOOLS SHALL BE USED UNDER MHI SUPERVISION

T

RG

36

03HNC0 1AN1

1-3

SUPPORTING TOOL

IDF

B07200-0002-001003

2 SET

FOR FF COUPLING

N29-10M-7096

24.9kg

ASSEMBLING PARTS - ADJUSTING BOLTS: M30x1.5 (2PC) - NUT: M30x1.5 (2PC) SPECIAL TOOLS SHALL BE USED UNDER MHI SUPERVISION

T

RG

37

03HNC0 1AN1

1-4

JOINT BAR ASSEMBLY

IDF

B07200-0002-001-

10 SET

004

FOR SUPPORTING TOOL

N29-10M-7096

4.5 kg

ASSEMBLING PARTS - PIN : 5 PCS - BEARING: NAST 50R (5 PC) - RETAINING RING:50 (5PC) SPECIAL TOOLS SHALL BE USED UNDER MHI SUPERVISION

T

RG

38

39

03HNC0 1AN1

1-5

03HNC0 1AN1

2

BOLT NUT M16x46

IDF

SPANNER

IDF

B07200-0002-001-

18 SET

FOR SUPPORTING TOOL

N29-10M-7096

0.141 kg

1 SET

FOR M/B FASTENING NUT

N29-10M-7096

1.12 kg

005

B07200-0002-002001

SPECIAL TOOLS SHALL BE USED UNDER MHI SUPERVISION

SPECIAL TOOLS SHALL BE USED UNDER MHI SUPERVISION

MM-M02.02

Rev.003

T

RG

Induced Draft Fan Mitsubishi

C-2

Appendix C

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

PJ No.

T

T

T

T

T

RG

RG

RG

RG

RG

40

41

03HNC0 1AN1

42

43

44

45

03HNC0 1AN1

03HNC0 1AN1

3-1

3-2

3-3

3-4

03HNC0 1AN1

4-1

03HNC0 1AN1

4-2

Special Tool Name/ Description

INSERT PIECE

PLATE

BOLT, NUT M12

WIRE BAND 150

GUIDE

TIGHTENING PLATE

Name of Equipment for which special tools used

Suppliers ID No. (Note 2)

IDF

B07200-0002-003001

IDF

IDF

IDF

IDF

IDF

B07200-0002-003002

B07200-0002-003003

B07200-0002-003-

Total Qty. Supplied for Plant

Purpose

1

FOR MOVING BLADE ARM BUSH

1

FOR MOVING BLADE ARM BUSH

1 SET

FOR MOVING BLADE ARM BUSH

2 SET

FOR MOVING BLADE ARM BUSH

1

FOR MV PACKING

1

FOR MV PACKING

004

B07200-0002-004001

B07200-0002-004002

Ref. Instruction / Doc/Dwgs(Note # 3)

Outline view & Dimensions (Note # 4)

Weight

Remarks

2.3 kg

SPECIAL TOOLS SHALL BE USED UNDER MHI SUPERVISION

0.93 kg

SPECIAL TOOLS SHALL BE USED UNDER MHI SUPERVISION

0.25kg

SPECIAL TOOLS SHALL BE USED UNDER MHI SUPERVISION

0.08 kg

SPECIAL TOOLS SHALL BE USED UNDER MHI SUPERVISION

N29-10M-7096

3.8 kg

SPECIAL TOOLS SHALL BE USED UNDER MHI SUPERVISION

N29-10M-7096

2.8 kg

SPECIAL TOOLS SHALL BE USED UNDER MHI SUPERVISION

-

-

-

-

MM-M02.02

Rev.003

T

RG

03HNC0 1AN1

Tool ID

IDF SPECIAL TOOL LIST (2 OF 8)

Induced Draft Fan Mitsubishi

C-3

Appendix C

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

PJ No.

Tool ID

Special Tool Name/ Description

Name of Equipment for which special tools used

Suppliers ID No. (Note 2)

IDF SPECIAL TOOL LIST (3 OF 8)

Total Qty. Supplied for Plant

Purpose

Ref. Instruction / Doc/Dwgs(Note # 3)

Outline view & Dimensions (Note # 4)

Weight

Remarks

FOR CYLINDER T

RG

46

03HNC0 1AN1

4-3

INSERT RING

IDF

B07200-0002-004003

1

FOR MV PACKING

N29-10M-7096

2.6 kg

SPECIAL TOOLS SHALL BE USED UNDER MHI SUPERVISION

FOR CYLINDER T

RG

47

03HNC0 1AN1

4-4

GUIDE BAR & NUT M10

IDF

B07200-0002-004004

3 SET

FOR MV PACKING

N29-10M-7096

0.19 kg

SPECIAL TOOLS SHALL BE USED UNDER MHI SUPERVISION

FOR CYLINDER COVER T

RG

48

03HNC0 1AN1

5-1

GUIDE RING

IDF

B07200-0002-005001

1

FOR MV PACKING

N29-10M-7096

4.5kg

SPECIAL TOOLS SHALL BE USED UNDER MHI SUPERVISION

FOR CYLINDER COVER T

RG

49

03HNC0 1AN1

5-2

TIGHTENING PLATE

IDF

B07200-0002-005-

1

002

FOR MV PACKING

N29-10M-7096

4.0 kg

SPECIAL TOOLS SHALL BE USED UNDER MHI SUPERVISION

FOR CYLINDER COVER T

RG

50

03HNC0 1AN1

5-3

INSERT RING

IDF

B07200-0002-005-

1

003

FOR MV PACKING

N29-10M-7096

3.4 kg

SPECIAL TOOLS SHALL BE USED UNDER MHI SUPERVISION

FOR CYLINDER COVER RG

51

03HNC0 1AN1

5-4

GUIDE BAR & NUT (M10)

IDF

B07200-0002-005004

3 SET

FOR MV PACKING

N29-10M-7096

0.19 kg

SPECIAL TOOLS SHALL BE USED UNDER MHI SUPERVISION

MM-M02.02

Rev.003

T

Induced Draft Fan Mitsubishi

C-4

Appendix C

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

PJ No.

T

T

T

T

T

RG

RG

RG

RG

RG

Special Tool Name/ Description

Name of Equipment for which special tools used

Suppliers ID No. (Note 2)

B07200-0002-006001

52

03HNC0 1AN1

6-1

RING SPANNER

IDF

53

03HNC0 1AN1

6-2

BOLTM16x50

IDF

03HNC0 1AN1

7-1

03HNC0 1AN1

7-2

03HNC0 1AN1

8-1

03HNC0 1AN1

8-2

54

55

56

57

DRAW OUT TOOL

IDF

BOLT & NUT M20

IDF

DRAW OUT TOOL

IDF

GUIDE BAR & NUT M20

IDF

B07200-0002-006002

B07200-0002-007001

B07200-0002-007-

Total Qty. Supplied for Plant

Purpose

1

FOR NUT & PISTON

4

Ref. Instruction / Doc/Dwgs(Note # 3)

Outline view & Dimensions (Note # 4)

Weight

Remarks

-

9.0 kg

SPECIAL TOOLS SHALL BE USED UNDER MHI SUPERVISION

FOR NUT & PISTON

-

0.119 kg

SPECIAL TOOLS SHALL BE USED UNDER MHI SUPERVISION

1SET

FOR PISTON

N29-10M-7096

21.0kg

SPECIAL TOOLS SHALL BE USED UNDER MHI SUPERVISION

2SET

FOR PISTON

N29-10M-7096

0.76 kg

SPECIAL TOOLS SHALL BE USED UNDER MHI SUPERVISION

1SET

FOR PILOT SLEEVE

N29-10M-7096

7.0 kg

SPECIAL TOOLS SHALL BE USED UNDER MHI SUPERVISION

2SET

FOR PILOT SLEEVE

N29-10M-7096

1.56 kg

SPECIAL TOOLS SHALL BE USED UNDER MHI SUPERVISION

002

B07200-0002-008001

B07200-0002-008001

MM-M02.02

Rev.003

T

RG

Tool ID

IDF SPECIAL TOOL LIST (4 OF 8)

Induced Draft Fan Mitsubishi

C-5

Appendix C

TABLE C-1

T

T

T

T

T

RG

RG

RG

RG

RG

Suppliers ID No. (Note 2)

Total Qty. Supplied for Plant

Purpose

Ref. Instruction / Doc/Dwgs(Note # 3)

BOLT M8x20

IDF

B07200-0002-008003

6

FOR PILOT SLEEVE

SPANNER

IDF

1 SET

Tool ID

Special Tool Name/ Description

58

03HNC0 1AN1

8-3

59

03HNC0 1AN1

9-1

03HNC0 1AN1

9-2

03HNC0 1AN1

9-3

03HNC0 1AN1

9-4

03HNC0 1AN1

9-5

60

61

62

63

FITTING PLATE

FITTING PIECE

FITTING PIECE

SPACER

IDF

IDF

IDF

IDF

B07200-0002-009001

B07200-0002-009002

B07200-0002-009-

Weight

Remarks

N29-10M-7096

0.013 kg

SPECIAL TOOLS SHALL BE USED UNDER MHI SUPERVISION

FASTENING NUT FOR ROTOR DISK

N29-10M-7096-

117.8 kg

SPECIAL TOOLS SHALL BE USED UNDER MHI SUPERVISION

2 SET

FASTENING NUT FOR ROTOR DISK

N29-10M-7096

14.4kg

SPECIAL TOOLS SHALL BE USED UNDER MHI SUPERVISION

2 SET

FASTENING NUT FOR ROTOR DISK

N29-10M-7096

4.9 kg

SPECIAL TOOLS SHALL BE USED UNDER MHI SUPERVISION

2

FASTENING NUT FOR ROTOR DISK

N29-10M-7096

5.0 kg

SPECIAL TOOLS SHALL BE USED UNDER MHI SUPERVISION

2

FASTENING NUT FOR ROTOR DISK

N29-10M-7096

1.2 kg

SPECIAL TOOLS SHALL BE USED UNDER MHI SUPERVISION

003

B07200-0002-009004

B07200-0002-009005

Outline view & Dimensions (Note # 4)

MM-M02.02

Rev.003

T

RG

Name of Equipment for which special tools used

Eqt. ID *(Note 1)

PJ No.

IDF SPECIAL TOOL LIST (5 OF 8)

Induced Draft Fan Mitsubishi

C-6

Appendix C

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

Tool ID

Special Tool Name/ Description

64

03HNC0 1AN1

9-6

BOLT M30x50

65

03HNC0 1AN1

9-7

03HNC0 1AN1

10-1

03HNC0 1AN1

10-2

PJ No.

T

T

T

T

T

T

T

RG

RG

RG

RG

RG

RG

RG

66

67

68

69

70

71

03HNC0 1AN1

10-3

03HNC0 1AN1

10-4

03HNC0 1AN1

11-1

03HNC0 1AN1

11-2

CYLINDER

Name of Equipment for which special tools used

Suppliers ID No. (Note 2)

Total Qty. Supplied for Plant

Purpose

Ref. Instruction / Doc/Dwgs(Note # 3)

IDF

B07200-0002-009006

6 SET

FASTENING NUT FOR ROTOR DISK

N29-10M-7096

2 SET

FASTENING NUT FOR ROTOR DISK

1

IDF

SOCKET WRENCH M30

IDF

SOCKET WRENCH M22

IDF

SOCKET WRENCH M42

SOCKET WRENCH M30

SPECIAL EYE BOLT

SPECIAL EYE BOLT

IDF

IDF

IDF

IDF

B07200-0002-009007

B07200-0002-010001

B07200-0002-010-

Weight

Remarks

0.58 kg

SPECIAL TOOLS SHALL BE USED UNDER MHI SUPERVISION

N29-10M-7096-

2.0 kg

SPECIAL TOOLS SHALL BE USED UNDER MHI SUPERVISION

FOR TORQUE WRENCH

-

3.14kg

SPECIAL TOOLS SHALL BE USED UNDER MHI SUPERVISION

1

FOR TORQUE WRENCH

-

0.67 kg

SPECIAL TOOLS SHALL BE USED UNDER MHI SUPERVISION

1

FOR SOCKET HEAD BOLT

-

1.6 kg

SPECIAL TOOLS SHALL BE USED UNDER MHI SUPERVISION

1

FOR SOCKET HEAD BOLT

-

1.2 kg

SPECIAL TOOLS SHALL BE USED UNDER MHI SUPERVISION

2

FOR ROTOR

-

3.5 kg

SPECIAL TOOL SHALL BE USED UNDER MHI SUPERVISION

4

FOR ROTOR

-

24.5 kg

SPECIAL TOOLS SHALL BE USED UNDER MHI SUPERVISION

002

B07200-0002-010003

B07200-0002-010004

B07200-0002-011-

Outline view & Dimensions (Note # 4)

001

B07200-0002-011002

MM-M02.02

Rev.003

T

RG

IDF SPECIAL TOOL LIST (6 OF 8)

Induced Draft Fan Mitsubishi

C-7

Appendix C

TABLE C-1

T

T

T

T

T

T

T

RG

RG

RG

RG

RG

RG

RG

Suppliers ID No. (Note 2)

Total Qty. Supplied for Plant

Purpose

Ref. Instruction / Doc/Dwgs(Note # 3)

INSERT PIECE

IDF

B07200-0002-012001

1

FOR BUSH M/B SHAFT

INSERT PIECE

IDF

1

Tool ID

Special Tool Name/ Description

72

03HNC0 1AN1

12-1

73

03HNC0 1AN1

12-2

03HNC0 1AN1

12-3

03HNC0 1AN1

12-4

03HNC0 1AN1

13-1

03HNC0 1AN1

13-2

74

75

76

77

78

79

03HNC0 1AN1

14-1

03HNC0 1AN1

14-2

DISTANCE SLEEVE

IDF

BOLT & NUT M16

IDF

GUIDE TOOL

NUT M20

WRENCH

WRENCH

IDF

IDF

IDF

IDF

B07200-0002-012002

B07200-0002-012003

B07200-0002-012-

Weight

Remarks

N29-10M-7096

2.0 kg

SPECIAL TOOLS SHALL BE USED UNDER MHI SUPERVISION

FOR BUSH M/B SHAFT

N29-10M-7096-

1.9 kg

SPECIAL TOOLS SHALL BE USED UNDER MHI SUPERVISION

1

FOR BUSH M/B SHAFT

-

0.16 kg

SPECIAL TOOLS SHALL BE USED UNDER MHI SUPERVISION

1 SET

FOR BUSH M/B SHAFT

-

0.41 kg

SPECIAL TOOLS SHALL BE USED UNDER MHI SUPERVISION

4

FOR CASING

-

3.5 kg

SPECIAL TOOLS SHALL BE USED UNDER MHI SUPERVISION

12

FOR CASING

-

0.059 kg

SPECIAL TOOLS SHALL BE USED UNDER MHI SUPERVISION

1

FOR OPERATION SHAFT NUT

-

23.0 kg

SPECIAL TOOL SHALL BE USED UNDER MHI SUPERVISION

1

FOR OPERATION SHAFT NUT

-

18.8 kg

SPECIAL TOOLS SHALL BE USED UNDER MHI SUPERVISION

004

B07200-0002-013001

B07200-0002-013-

Outline view & Dimensions (Note # 4)

002

B07200-0002-014001

B07200-0002-014002

MM-M02.02

Rev.003

T

RG

Name of Equipment for which special tools used

Eqt. ID *(Note 1)

PJ No.

IDF SPECIAL TOOL LIST (6 OF 8)

Induced Draft Fan Mitsubishi

C-8

Appendix C

TABLE C-1

T

T

T

T

T

T

T

RG

RG

RG

RG

RG

RG

RG

Suppliers ID No. (Note 2)

Total Qty. Supplied for Plant

Purpose

Ref. Instruction / Doc/Dwgs(Note # 3)

GUIDE BAR

IDF

B07200-0002-015001

2

FOR CYLINDER COVER

NUT TM30

IDF

2

Tool ID

Special Tool Name/ Description

80

03HNC0 1AN1

15-1

81

03HNC0 1AN1

15-2

03HNC0 1AN1

15-3

03HNC0 1AN1

15-4

03HNC0 1AN1

16

82

83

84

85

86

87

03HNC0 1AN1

17

03HNC0 1AN1

18

03HNC0 1AN1

19-1

GUIDE BAR

NUT TM42

GUIDE TOOL

SOCKET WRENCH

IDF

IDF

IDF

IDF

TORQUE WRENCH

IDF

BOX WRENCH FOR S-65

IDF

B07200-0002-015002

B07200-0002-015003

B07200-0002-015-

Weight

Remarks

-

1.81kg

SPECIAL TOOLS SHALL BE USED UNDER MHI SUPERVISION

FOR CYLINDER COVER

-

0.21kg

SPECIAL TOOLS SHALL BE USED UNDER MHI SUPERVISION

2

FOR CYLINDER

-

3.8kg

SPECIAL TOOLS SHALL BE USED UNDER MHI SUPERVISION

2

FOR CYLINDER

-

0.58kg

SPECIAL TOOLS SHALL BE USED UNDER MHI SUPERVISION

2

FOR OPERATING SHAFT BUSH

-

11.4kg

SPECIAL TOOLS SHALL BE USED UNDER MHI SUPERVISION

2

FOR TORQUE LIMITER

1.10kg

SPECIAL TOOLS SHALL BE USED UNDER MHI SUPERVISION

004

B07200-0002-016000

B07200-0002-017000

B07200-0002-018-

Outline view & Dimensions (Note # 4)

-

1 SET

FOR BOLT

-

21.1kg

SPECIAL TOOL SHALL BE USED UNDER MHI SUPERVISION

1

FOR FF COUPLING

-

5.1kg

SPECIAL TOOLS SHALL BE USED UNDER MHI SUPERVISION

000

B07200-0002-019001

MM-M02.02

Rev.003

T

RG

Name of Equipment for which special tools used

Eqt. ID *(Note 1)

PJ No.

IDF SPECIAL TOOL LIST (7 OF 8)

Induced Draft Fan Mitsubishi

C-9

Appendix C

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

Tool ID

Special Tool Name/ Description

Name of Equipment for which special tools used

Suppliers ID No. (Note 2)

Total Qty. Supplied for Plant

Purpose

Ref. Instruction / Doc/Dwgs(Note # 3)

88

03HNC0 1AN1

19-2

STRIKING FACE RING SPANNER

IDF

B07200-0002-019002

1

FOR FF COUPLING

89

03HNC0 1AN1

19-3

STRIKING FACE OPEN END SPANNER

IDF

1

03HNC0 1AN1

20-1

GAS CHARGING 3-WAY VALVE (M3-G02)

IDF

03HNC0 1AN1

20-2

HOSE (H210-L02)

IDF

PRESSURE GAUGE (AT1/4x60x 6MPa)

IDF

ADAPTER (AD-23)

IDF

PJ No.

T

T

T

T

T

T

RG

RG

RG

RG

RG

RG

90

91

92

93

94

03HNC0 1AN1

20-3

03HNC0 1AN1

20-4

03HNC0 1AN1

20-5

CUP NUT WRENCH (TWG81)

IDF

B07200-0002-019003

B07200-0002-020001

B07200-0002-020-

Weight

Remarks

-

4.4kg

SPECIAL TOOLS SHALL BE USED UNDER MHI SUPERVISION

FOR FF COUPLING

-

7.5kg

SPECIAL TOOLS SHALL BE USED UNDER MHI SUPERVISION

1

FOR ACCUMULATOR

-

0.48kg

SPECIAL TOOLS SHALL BE USED UNDER MHI SUPERVISION

1

FOR ACCUMULATOR

-

0.64

SPECIAL TOOLS SHALL BE USED UNDER MHI SUPERVISION

1

FOR ACCUMULATOR

-

0.18kg

SPECIAL TOOLS SHALL BE USED UNDER MHI SUPERVISION

1

FOR ACCUMULATOR

-

0.18kg

SPECIAL TOOLS SHALL BE USED UNDER MHI SUPERVISION

1

FOR ACCUMULATOR

1.4kg

SPECIAL TOOL SHALL BE USED UNDER MHI SUPERVISION

002

B07200-0002-020003

B07200-0002-020004

B07200-0002-020005

Outline view & Dimensions (Note # 4)

-

MM-M02.02

Rev.003

T

RG

IDF SPECIAL TOOL LIST (8 OF 8)

Induced Draft Fan Mitsubishi

C-10

Appendix D

A p p en d i x

D Coupling Alignment COUPLING ALIGNMENT (IDF) The following basic alignment procedure is suitable for fan coupling; 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 the shaft of the fan side or motor side 90°, check DTI reading at 90°.

3

Turn the shaft of the fan side or motor side a further 90°, check DTI reading at 180°.

4

Turn the shaft of the fan side or motor side a further 90°, check DTI reading at 270°.

5

Turn the shaft of the fan side or motor side to zero, recheck DTI reading at zero.

MM-M02.02

Rev.003

1

Induced 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 Peripheral Axial

0.05 mm 0.05 mm

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

Rev.003

Form Flex Coupling Maximum End Float:

±3.1 mm (0.10)

MM-M02.02

Maximum Lateral Misalignment:

Induced Draft Fan Mitsubishi

31.8 mm (0.50)

D-2

Appendix D

COUPLING ALIGNMENT (OTHER EQUIPMENT) 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-M02.02

Rev.003

1

Induced Draft Fan Mitsubishi

D-3

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:

Rigid Couplings Peripheral

0.05 mm

Peripheral

0.05 mm

The oil pump supplier, Daikin Inc. has mentioned the following specific installation acceptance criteria:

Rev.003

Motor to Pump Coupling Maximum Peripheral Misalignment:

MM-M02.02

Maximum Axial misalignment :

Induced Draft Fan Mitsubishi

0.05 mm (TIR)

0.08 mm (across coupling face)

D-4

Appendix E

Applicable Reference E & Vendor Drawings

MM-M02.02

Rev.003

A p p en d i x

Induced Draft Fan Mitsubishi

E-1

MM-M02.02

Rev.003

Appendix E

MPTD-3-0503

Induce Draft Fans Mitsubishi

FIGURE E-1

INDUCED DRAFT FAN OUTLINE DRAWING

E-2

MM-M02.02

Rev.003

Appendix E

MPTD-3-0504

Induce Draft Fans Mitsubishi

FIGURE E-2

INDUCED DRAFT FAN SECTIONAL DRAWING

E-3

Appendix E

MM-M02.02

Rev.003

ᴾ ᴾ

MPTD-3-0505

Induce Draft Fans Mitsubishi

FIGURE E-3

IDF LUBRICANT & CONTROL OIL SYSTEM P & ID

E-4

MM-M02.02

Rev.003

Appendix E

MPTD-3-0506

Induce Draft Fans Mitsubishi

FIGURE E-4

IDF-A LUBRICANT & CONTROL OIL SYSTEM UNIT ASSEMBLY – 1/2

E-5

MM-M02.02

Rev.003

Appendix E

MPTD-3-1209

Induce Draft Fans Mitsubishi

FIGURE E-5

IDF-A LUBRICANT & CONTROL OIL SYSTEM UNIT ASSEMBLY – 2/2

E-6

MM-M02.02

Rev.003

Appendix E

MPTD-3-1210

Induce Draft Fans Mitsubishi

FIGURE E-6

IDF-B LUBRICANT & CONTROL OIL SYSTEM UNIT ASSEMBLY – 1/2

E-7

MM-M02.02

Rev.003

Appendix E

MPTD-3-1211

Induce Draft Fans Mitsubishi

FIGURE E-7

IDF-B LUBRICANT & CONTROL OIL SYSTEM UNIT ASSEMBLY – 2/2

E-8

MM-M02.02

Rev.003

Appendix E

MPTD-3-1212

Induce Draft Fans Mitsubishi

FIGURE E-8

IDF SEAL AIR FAN OUTLINE DRAWING

E-9

MM-M02.02

Rev.003

Appendix E

MPTD-3-1213

Induce Draft Fans Mitsubishi

FIGURE E-9

IDF FORM FLEX COUPLING SECTIONAL DRAWING

E-10

Appendix F

A p p en d i x

MM-M02.02

Rev.003

F MV Packing Insertion

Induced 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 RUBBER PACKING

OUTER ADAPTER

SPECIAL TOOLS FOR THIS PROCEDURE ITEM ARE IN SPECIAL TOOLS LIST, APPENDIX C. MOD-4-0970

MM-M02.02

Rev.003

NOTE:

FIGURE F-1

Induced Draft Fan Mitsubishi

RUBBER PACKING

INNER ADAPTER MV PACKING

MV PACKING INSERTION

F-2

Appendix F

30 -NON-MOTOR SIDE 138 118 31

D d H

30 -MOTOR SIDE 165 140 37

Od

OD

H

1

ITEM

1 2 3 4

2

DESCRIPTION INNER ADAPTER MV PACKING RUBBER PACING OUTER ADAPTER

3

4

MATERIAL RUBBER RUBBER RUBBER RUBBER

MATERIAL AND DIMENSION

MM-M02.02

Rev.003

MOD-4-0971

FIGURE F-2

Induced Draft Fan Mitsubishi

MV PACKING MATERIAL & DIMENSION

F-3

Appendix G

A p p en d i x

G Applicable Vendors Manual Item No.

Description

1

Handling Manual of Lubrication Oil Unit for ID Fan

Daikin Hydraulic Engineering Co. Ltd. Japan

2

Handling Manual of Pleated Type Accumulator

Nippon Accumulator Co., Ltd. Japan

3

Instruction Manual of IDF Seal Air Fan

Azuma Sufoki Co., Ltd.

Handling Manual of FF Coupling

Daido Precision Industries, Ltd. Japan

Japan

MM-M02.02

Rev.003

4

Manufacturer

Induced Draft Fans Mitsubishi

G-1

Appendix G

APPENDIX G-1

HANDLING MANUAL OF IDF LUBRICATION & CONTROL OIL UNIT

Rev.003

VENDOR: DAIKIN HYDRAULIC ENGINEERING CO. LTD.

MM-M02.02

JAPAN

Induced Draft Fan Mitsubishi

G-2

MM-M02.02

Rev.003

Appendix G

Induced Draft Fan Mitsubishi

G-3

MM-M02.02

Rev.003

Appendix G

Induced Draft Fan Mitsubishi

G-4

MM-M02.02

Rev.003

Appendix G

Induced Draft Fan Mitsubishi

G-5

MM-M02.02

Rev.003

Appendix G

Induced Draft Fan Mitsubishi

G-6

MM-M02.02

Rev.003

Appendix G

Induced Draft Fan Mitsubishi

G-7

MM-M02.02

Rev.003

Appendix G

Induced Draft Fan Mitsubishi

G-8

MM-M02.02

Rev.003

Appendix G

Induced Draft Fan Mitsubishi

G-9

MM-M02.02

Rev.003

Appendix G

Induced Draft Fan Mitsubishi

G-10

MM-M02.02

Rev.003

Appendix G

Induced Draft Fan Mitsubishi

G-11

MM-M02.02

Rev.003

Appendix G

Induced Draft Fan Mitsubishi

G-12

MM-M02.02

Rev.003

Appendix G

Induced Draft Fan Mitsubishi

G-13

MM-M02.02

Rev.003

Appendix G

Induced Draft Fan Mitsubishi

G-14

MM-M02.02

Rev.003

Appendix G

Induced Draft Fan Mitsubishi

G-15

MM-M02.02

Rev.003

Appendix G

Induced Draft Fan Mitsubishi

G-16

MM-M02.02

Rev.003

Appendix G

Induced Draft Fan Mitsubishi

G-17

MM-M02.02

Rev.003

Appendix G

Induced Draft Fan Mitsubishi

G-18

MM-M02.02

Rev.003

Appendix G

Induced Draft Fan Mitsubishi

G-19

MM-M02.02

Rev.003

Appendix G

Induced Draft Fan Mitsubishi

G-20

MM-M02.02

Rev.003

Appendix G

Induced Draft Fan Mitsubishi

G-21

MM-M02.02

Rev.003

Appendix G

Induced Draft Fan Mitsubishi

G-22

MM-M02.02

Rev.003

Appendix G

Induced Draft Fan Mitsubishi

G-23

MM-M02.02

Rev.003

Appendix G

Induced Draft Fan Mitsubishi

G-24

Appendix G

MM-M02.02

Rev.003

24

Induced Draft Fan Mitsubishi

G-25

MM-M02.02

Rev.003

Appendix G

Induced Draft Fan Mitsubishi

G-26

MM-M02.02

Rev.003

Appendix G

Induced Draft Fan Mitsubishi

G-27

MM-M02.02

Rev.003

Appendix G

Induced Draft Fan Mitsubishi

G-28

MM-M02.02

Rev.003

Appendix G

Induced Draft Fan Mitsubishi

G-29

MM-M02.02

Rev.003

Appendix G

Induced Draft Fan Mitsubishi

G-30

MM-M02.02

Rev.003

Appendix G

Induced Draft Fan Mitsubishi

G-31

MM-M02.02

Rev.003

Appendix G

Induced Draft Fan Mitsubishi

G-32

MM-M02.02

Rev.003

Appendix G

Induced Draft Fan Mitsubishi

G-33

MM-M02.02

Rev.003

Appendix G

Induced Draft Fan Mitsubishi

G-34

MM-M02.02

Rev.003

Appendix G

Induced Draft Fan Mitsubishi

G-35

MM-M02.02

Rev.003

Appendix G

Induced Draft Fan Mitsubishi

G-36

MM-M02.02

Rev.003

Appendix G

Induced Draft Fan Mitsubishi

G-37

MM-M02.02

Rev.003

Appendix G

Induced Draft Fan Mitsubishi

G-38

MM-M02.02

Rev.003

Appendix G

Induced Draft Fan Mitsubishi

G-39

MM-M02.02

Rev.003

Appendix G

Induced Draft Fan Mitsubishi

G-40

MM-M02.02

Rev.003

Appendix G

Induced Draft Fan Mitsubishi

G-41

MM-M02.02

Rev.003

Appendix G

Induced Draft Fan Mitsubishi

G-42

MM-M02.02

Rev.003

Appendix G

Induced Draft Fan Mitsubishi

G-43

MM-M02.02

Rev.003

Appendix G

Induced Draft Fan Mitsubishi

G-44

MM-M02.02

Rev.003

Appendix G

Induced Draft Fan Mitsubishi

G-45

MM-M02.02

Rev.003

Appendix G

Induced Draft Fan Mitsubishi

G-46

MM-M02.02

Rev.003

Appendix G

Induced Draft Fan Mitsubishi

G-47

MM-M02.02

Rev.003

Appendix G

Induced Draft Fan Mitsubishi

G-48

MM-M02.02

Rev.003

Appendix G

Induced Draft Fan Mitsubishi

G-49

MM-M02.02

Rev.003

Appendix G

Induced Draft Fan Mitsubishi

G-50

MM-M02.02

Rev.003

Appendix G

Induced Draft Fan Mitsubishi

G-51

MM-M02.02

Rev.003

Appendix G

Induced Draft Fan Mitsubishi

G-52

MM-M02.02

Rev.003

Appendix G

Induced Draft Fan Mitsubishi

G-53

MM-M02.02

Rev.003

Appendix G

Induced Draft Fan Mitsubishi

G-54

MM-M02.02

Rev.003

Appendix G

Induced Draft Fan Mitsubishi

G-55

MM-M02.02

Rev.003

Appendix G

Induced Draft Fan Mitsubishi

G-56

MM-M02.02

Rev.003

Appendix G

Induced Draft Fan Mitsubishi

G-57

MM-M02.02

Rev.003

Appendix G

Induced Draft Fan Mitsubishi

G-58

MM-M02.02

Rev.003

Appendix G

Induced Draft Fan Mitsubishi

G-59

MM-M02.02

Rev.003

Appendix G

Induced Draft Fan Mitsubishi

G-60

MM-M02.02

Rev.003

Appendix G

Induced Draft Fan Mitsubishi

G-61

MM-M02.02

Rev.003

Appendix G

Induced Draft Fan Mitsubishi

G-62

MM-M02.02

Rev.003

Appendix G

Induced Draft Fan Mitsubishi

G-63

MM-M02.02

Rev.003

Appendix G

Induced Draft Fan Mitsubishi

G-64

MM-M02.02

Rev.003

Appendix G

Induced Draft Fan Mitsubishi

G-65

MM-M02.02

Rev.003

Appendix G

Induced Draft Fan Mitsubishi

G-66

MM-M02.02

Rev.003

Appendix G

Induced Draft Fan Mitsubishi

G-67

MM-M02.02

Rev.003

Appendix G

Induced Draft Fan Mitsubishi

G-68

MM-M02.02

Rev.003

Appendix G

Induced Draft Fan Mitsubishi

G-69

MM-M02.02

Rev.003

Appendix G

Induced Draft Fan Mitsubishi

G-70

MM-M02.02

Rev.003

Appendix G

Induced Draft Fan Mitsubishi

G-71

MM-M02.02

Rev.003

Appendix G

Induced Draft Fan Mitsubishi

G-72

MM-M02.02

Rev.003

Appendix G

Induced Draft Fan Mitsubishi

G-73

MM-M02.02

Rev.003

Appendix G

Induced Draft Fan Mitsubishi

G-74

MM-M02.02

Rev.003

Appendix G

Induced Draft Fan Mitsubishi

G-75

MM-M02.02

Rev.003

Appendix G

Induced Draft Fan Mitsubishi

G-76

MM-M02.02

Rev.003

Appendix G

Induced Draft Fan Mitsubishi

G-77

MM-M02.02

Rev.003

Appendix G

Induced Draft Fan Mitsubishi

G-78

MM-M02.02

Rev.003

Appendix G

Induced Draft Fan Mitsubishi

G-79

MM-M02.02

Rev.003

Appendix G

Induced Draft Fan Mitsubishi

G-80

MM-M02.02

Rev.003

Appendix G

Induced Draft Fan Mitsubishi

G-81

MM-M02.02

Rev.003

Appendix G

Induced Draft Fan Mitsubishi

G-82

MM-M02.02

Rev.003

Appendix G

Induced Draft Fan Mitsubishi

G-83

MM-M02.02

Rev.003

Appendix G

Induced Draft Fan Mitsubishi

G-84

MM-M02.02

Rev.003

Appendix G

Induced Draft Fan Mitsubishi

G-85

MM-M02.02

Rev.003

Appendix G

Induced Draft Fan Mitsubishi

G-86

MM-M02.02

Rev.003

Appendix G

Induced Draft Fan Mitsubishi

G-87

MM-M02.02

Rev.003

Appendix G

Induced Draft Fan Mitsubishi

G-88

MM-M02.02

Rev.003

Appendix G

Induced Draft Fan Mitsubishi

G-89

MM-M02.02

Rev.003

Appendix G

Induced Draft Fan Mitsubishi

G-90

MM-M02.02

Rev.003

Appendix G

Induced Draft Fan Mitsubishi

G-91

MM-M02.02

Rev.003

Appendix G

Induced Draft Fan Mitsubishi

G-92

MM-M02.02

Rev.003

Appendix G

Induced Draft Fan Mitsubishi

G-93

MM-M02.02

Rev.003

Appendix G

Induced Draft Fan Mitsubishi

G-94

MM-M02.02

Rev.003

Appendix G

Induced Draft Fan Mitsubishi

G-95

Appendix G

APPENDIX G - 2

HANDLING MANUAL PLEATED TYPE ACCUMULATOR

VENDOR: Rev.003

NIPPON ACCUMULATOR CO., LTD.

MM-M02.02

JAPAN

Induced Draft Fan Mitsubishi

G-96

MM-M02.02

Rev.003

Appendix G

Induced Draft Fan Mitsubishi

G-97

MM-M02.02

Rev.003

Appendix G

Induced Draft Fan Mitsubishi

G-98

MM-M02.02

Rev.003

Appendix G

Induced Draft Fan Mitsubishi

G-99

MM-M02.02

Rev.003

Appendix G

Induced Draft Fan Mitsubishi

G-100

MM-M02.02

Rev.003

Appendix G

Induced Draft Fan Mitsubishi

G-101

MM-M02.02

Rev.003

Appendix G

Induced Draft Fan Mitsubishi

G-102

MM-M02.02

Rev.003

Appendix G

Induced Draft Fan Mitsubishi

G-103

MM-M02.02

Rev.003

Appendix G

Induced Draft Fan Mitsubishi

G-104

MM-M02.02

Rev.003

Appendix G

Induced Draft Fan Mitsubishi

G-105

MM-M02.02

Rev.003

Appendix G

Induced Draft Fan Mitsubishi

G-106

MM-M02.02

Rev.003

Appendix G

Induced Draft Fan Mitsubishi

G-107

MM-M02.02

Rev.003

Appendix G

Induced Draft Fan Mitsubishi

G-108

MM-M02.02

Rev.003

Appendix G

Induced Draft Fan Mitsubishi

G-109

MM-M02.02

Rev.003

Appendix G

Induced Draft Fan Mitsubishi

G-110

MM-M02.02

Rev.003

Appendix G

Induced Draft Fan Mitsubishi

G-111

MM-M02.02

Rev.003

Appendix G

Induced Draft Fan Mitsubishi

G-112

MM-M02.02

Rev.003

Appendix G

Induced Draft Fan Mitsubishi

G-113

MM-M02.02

Rev.003

Appendix G

Induced Draft Fan Mitsubishi

G-114

MM-M02.02

Rev.003

Appendix G

Induced Draft Fan Mitsubishi

G-115

MM-M02.02

Rev.003

Appendix G

Induced Draft Fan Mitsubishi

G-116

MM-M02.02

Rev.003

Appendix G

Induced Draft Fan Mitsubishi

G-117

MM-M02.02

Rev.003

Appendix G

Induced Draft Fan Mitsubishi

G-118

MM-M02.02

Rev.003

Appendix G

Induced Draft Fan Mitsubishi

G-119

MM-M02.02

Rev.003

Appendix G

Induced Draft Fan Mitsubishi

G-120

Appendix G

APPENDIX G - 3

INSTRUCTION MANUAL OF IDF SEAL AIR FAN

VENDOR: Rev.003

AZUMA SUFOKI CO., LTD.

MM-M02.02

JAPAN

Induced Draft Fan Mitsubishi

G-121

MM-M02.02

Rev.003

Appendix G

Induced Draft Fan Mitsubishi

G-122

MM-M02.02

Rev.003

Appendix G

Induced Draft Fan Mitsubishi

G-123

MM-M02.02

Rev.003

Appendix G

Induced Draft Fan Mitsubishi

G-124

MM-M02.02

Rev.003

Appendix G

Induced Draft Fan Mitsubishi

G-125

MM-M02.02

Rev.003

Appendix G

Induced Draft Fan Mitsubishi

G-126

MM-M02.02

Rev.003

Appendix G

Induced Draft Fan Mitsubishi

G-127

MM-M02.02

Rev.003

Appendix G

Induced Draft Fan Mitsubishi

G-128

MM-M02.02

Rev.003

Appendix G

Induced Draft Fan Mitsubishi

G-129

MM-M02.02

Rev.003

Appendix G

Induced Draft Fan Mitsubishi

G-130

MM-M02.02

Rev.003

Appendix G

Induced Draft Fan Mitsubishi

G-131

MM-M02.02

Rev.003

Appendix G

Induced Draft Fan Mitsubishi

G-132

MM-M02.02

Rev.003

Appendix G

Induced Draft Fan Mitsubishi

G-133

MM-M02.02

Rev.003

Appendix G

Induced Draft Fan Mitsubishi

G-134

MM-M02.02

Rev.003

Appendix G

Induced Draft Fan Mitsubishi

G-135

Appendix G

APPENDIX – G- 4

Rev.003

HANDLING MANUAL OF FORM-FLEX COUPLING

VENDOR :

MM-M02.02

DAIDO PRECISION INDUSTRIES, CO. LTD. JAPAN Induced Draft Fan Mitsubishi

G-136

MM-M02.02

Rev.003

Appendix G

Induced Draft Fan Mitsubishi

G-137

MM-M02.02

Rev.003

Appendix G

Induced Draft Fan Mitsubishi

G-138

MM-M02.02

Rev.003

Appendix G

Induced Draft Fan Mitsubishi

G-139

MM-M02.02

Rev.003

Appendix G

Induced Draft Fan Mitsubishi

G-140

MM-M02.02

Rev.003

Appendix G

Induced Draft Fan Mitsubishi

G-141

MM-M02.02

Rev.003

Appendix G

Induced Draft Fan Mitsubishi

G-142

MM-M02.02

Rev.003

Appendix G

Induced Draft Fan Mitsubishi

G-143

MM-M02.02

Rev.003

Appendix G

Induced Draft Fan Mitsubishi

G-144

MM-M02.02

Rev.003

Appendix G

Induced Draft Fan Mitsubishi

G-145

MM-M02.02

Rev.003

Appendix G

Induced Draft Fan Mitsubishi

G-146

MM-M02.02

Rev.003

Appendix G

Induced Draft Fan Mitsubishi

G-147

MM-M02.02

Rev.003

Appendix G

Induced Draft Fan Mitsubishi

G-148

MM-M02.02

Rev.003

Appendix G

Induced Draft Fan Mitsubishi

G-149

MM-M02.02

Rev.003

Appendix G

Induced Draft Fan Mitsubishi

G-150

Appendix H

A p p en d i x

MM-M02.02

Rev.003

H Parts List

Induced Draft Fan Mitsubishi

H-1

MM-M02.02

Rev.003

Appendix H

Induced Draft Fan Mitsubishi

H-2

MM-M02.02

Rev.003

Appendix H

Induced Draft Fan Mitsubishi

H-3

MM-M02.02

Rev.003

Appendix H

Induced Draft Fan Mitsubishi

H-4

MM-M02.02

Rev.003

Appendix H

Induced Draft Fan Mitsubishi

H-5

MM-M02.02

Rev.003

Appendix H

Induced Draft Fan Mitsubishi

H-6

MM-M02.02

Rev.003

Appendix H

Induced Draft Fan Mitsubishi

H-7

MM-M02.02

Rev.003

Appendix H

Induced Draft Fan Mitsubishi

H-8

MM-M02.02

Rev.003

Appendix H

Induced Draft Fan Mitsubishi

H-9

MM-M02.02

Rev.003

Appendix H

Induced Draft Fan Mitsubishi

H-10

MM-M02.02

Rev.003

Appendix H

Induced Draft Fan Mitsubishi

H-11

MM-M02.02

Rev.003

Appendix H

Induced Draft Fan Mitsubishi

H-12

MM-M02.02

Rev.003

Appendix H

Induced Draft Fan Mitsubishi

H-13

MM-M02.02

Rev.003

Appendix H

Induced Draft Fan Mitsubishi

H-14

MM-M02.02

Rev.003

Appendix H

Induced Draft Fan Mitsubishi

H-15

MM-M02.02

Rev.003

Appendix H

Induced Draft Fan Mitsubishi

H-16

MM-M02.02

Rev.003

Appendix H

Induced Draft Fan Mitsubishi

H-17

MM-M02.02

Rev.003

Appendix H

Induced Draft Fan Mitsubishi

H-18

MM-M02.02

Rev.003

Appendix H

Induced Draft Fan Mitsubishi

H-19

MM-M02.02

Rev.003

Appendix H

Induced Draft Fan Mitsubishi

H-20

MM-M02.02

Rev.003

Appendix H

Induced Draft Fan Mitsubishi

H-21

MM-M02.02

Rev.003

Appendix H

Induced Draft Fan Mitsubishi

H-22

MM-M02.02

Rev.003

Appendix H

Induced Draft Fan Mitsubishi

H-23

MM-M02.02

Rev.003

Appendix H

Induced Draft Fan Mitsubishi

H-24

MM-M02.02

Rev.003

Appendix H

Induced Draft Fan Mitsubishi

H-25

MM-M02.02

Rev.003

Appendix H

Induced Draft Fan Mitsubishi

H-26

MM-M02.02

Rev.003

Appendix H

Induced Draft Fan Mitsubishi

H-27

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