FGD & Ash Handling Maintenance Manual

A 2013.10.
20 FIRST SUBMISSION LiuXing LiWenke ChenJinghai

REV. DATE DESCRIPTION PREPARED CHECKED APPROVED
REVISION
OWNER IDENTIFICATION No.:
REV.:
OWNER: CONSULTANT:
VIETNAM ELECTRICITY POWER ENGINEERING CONSULTING
VINH TAN THERMAL POWER MANAGEMENT BOARD J.S.C 2 (PECC2)
EPC
CONTRACTOR: SHANGHAI ELECTRIC GROUP CO.,LTD.
COMPILE:
CHD POWER PLANT OPERATION CO.,LTD.
PROJECT: DESIGN STAGE:
VINH TAN 2 2×622MW THERMAL POWER PLANT Detail Design
APPROVED ChenJinghai CHECKED LiWenke

脱硫除灰维护手册
REVIEWED HuJiabing PREPARED LiuXing FGD&Ash handling Maintenance Manual
DATE 2013.10.20 SCALE N/A
DRAWING No. YXZL-WH-C-001 REV A
.
Vietnam Vinh Tan Phase II 2×622MW Coal Fired Power Generation Unit
Contents
1. Overview ....................................................................................................................................................... 1
1.1 Main engine device model .................................................................................................................. 1
1.2 Overview ............................................................................................................................................. 1
1.3 Flue gas system ................................................................................................................................... 2
1.4 SO2 absorption system......................................................................................................................... 2
1.5 Seawater supply system....................................................................................................................... 3
1.6 Seawater recovery system ................................................................................................................... 3
1.7 Other auxiliary systems ....................................................................................................................... 3
2. Equipment specifications ................................................................................................................................. 4
2.1 Flue gas desulfurization (FGD) system performance .......................................................................... 4
2.2 Equipment specifications .................................................................................................................... 5
3. Maintenance and overhaul of flue gas desulfurization (FGD) system devices ................................................ 6
3.1 Overhaul and maintenance items of all levels ..................................................................................... 7
3.2 Main equipment maintenance process and quality requirement.........................................................11
4. Dirt catcher equipment maintenance and overhauling ................................................................................... 17
4.1 Electric precipitator equipment overview ............................................................................................ 17
4.2 Equipment specification .................................................................................................................... 17
4.3 Safety tips (precautions) .................................................................................................................... 19
4.4 Maintenance items............................................................................................................................. 20
4.5 Equipment parts maintenance methods and precautions ................................................................... 21
4.6 Acceptance, test run, test and summary ............................................................................................ 24
4.7 General fault and handling methods during electric precipitator operation ...................................... 25
5. Pneumatic ash conveying equipment maintenance and overhauling ............................................................. 30
5.1 Overview ........................................................................................................................................... 30
5.2 Equipment specifications .................................................................................................................. 30
5.3 System layout .................................................................................................................................... 31
5.4 Pneumatic ash conveying system maintenance technology and quality standard ............................. 32
5.5 Ordinary maintenance and fault shooting.......................................................................................... 35
6. Equipment maintenance and overhaul of ash silo unloading system ............................................................. 36
6.1 Overview ........................................................................................................................................... 36
6.2 Main equipment specification ........................................................................................................... 36
6.3 Overhaul technology and quality standard of ash silo unloading system .......................................... 40
6.4 Daily maintenance and troubleshooting ............................................................................................ 45
Maintenance Manual on Ash Handling & Flue Gas Desulfurization
I
7. Operation specification of slag discharging system ....................................................................................... 49

7.1 Overview ........................................................................................................................................... 49
7.2 Main equipment specification ........................................................................................................... 49
7.3 Overhaul technology and quality standard of deslagging system ..................................................... 54
7.4 Daily maintenance and troubleshooting ............................................................................................ 61
8. Appendix: ....................................................................................................................................................... 63
8.1 General precaution for common overhaul ......................................................................................... 63
8.2 Low voltage motor maintenance manual .......................................................................................... 63
8.3 Valve maintenance manual ................................................................................................................ 67
8.4 Water pump maintenance manual...................................................................................................... 69

II
1. Overview
1.1 Main engine device model

1.1.1 Vietnam Vinh Tan Phase II Project (2×622MW subcritical unit) is of subcritical natural circulation
boiler, with single furnace, single reheat, balanced ventilation, outdoor arrangement, dry ash extraction, full
steel structure, W-shape flame combustion, vertical rifled water wall, II-type boiler. The roof is equipped with
large shell.
1.1.2 Steam turbine model: N622-16.67/538/538 steam turbine is of subcritical, reheating, three-cylinder
four-exhaust, condensing turbo-generator unit.
1.1.3 Generator model: QFSN-622-2 static-excited generator.
1.2 Overview
1.2.1 Seawater flue gas desulfurization (FGD) is used with seawater as the desulfurizer to remove SO2 in
flue gas, mainly including flue gas system, SO2 absorption system, seawater supply system, seawater
recovery system and the supporting electric, instrumentation and control systems.
1.2.2 A part of seawater from condenser enters counter-flow packed absorption tower, is distributed to the
packing surface evenly through seawater distributor. The original flue gas enters the absorption tower bottom,
fully contacts with seawater at packing layer, and SO2 in flue gas is absorbed by the seawater to generate
sulfite SO32- and hydrogen ion H+. H+ makes the seawater in acidity and the increase of H+ concentration in
seawater declines PH value for this part of seawater to form acidic seawater. The acidic seawater discharged
from absorption tower flows into seawater recovery system due to gravity, and this part of acidic seawater is
mixed with more original seawater from condenser (alkaline) in mixture zone. The mixed seawater is of PH
value increased to 5 or so, and a large quantity of air enters through aeration diffusion device (aerator), which
can efficiently create a large quantity of fine bubbles to recover chemical oxygen demand (COD) and
dissolved oxygen (DO) in seawater and oxidize sulfite into stable sulfate ion, and a large quantity of CO2 can
also be released from seawater through aeration so as to move equilibrium position of neutralization action to
the right and consume more H+ icons in seawater to recover PH value in the seawater and increase to over 6.8
and recover COD, DO, etc. to the requirements on water quality standard, finally discharge the qualified
seawater back to the sea. Main chemical reaction equations are stated as follows,
In absorption tower,
SO2 (gas)  SO2 (dissolved into seawater)
SO2 (dissolved into seawater) + H2O SO32- + 2H+
In aeration basin,
SO32- + 1/2 O2 (gas)  SO42-
CO32- + H+  HCO3-
HCO3- + H+  CO2 (gas+ dissolved into seawater) + H2O
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General chemical reaction quotations are stated as follows,

SO2 (gas) + H2O + 1/2O2 (gas)= SO42- + 2H+
HCO3- + H+ = CO2 (gas+ dissolved into seawater) + H2O
The sulfate finally generated by SO2 absorption with seawater is a harmless substance. The sulfate is
main component of salt content in seawater, and is essential to marine organisms.
1.3 Flue gas system
1.3.1 Each unit is equipped with a desulfurization booster fan. The booster fan is a fixed-blade adjustable
axial fan located at FGD upstream original flue gas side, and can guarantee good operating condition due to
small flue gas corrosive environment.
1.3.2 Adopt double baffle valve (having good sealing performance) with sealing air as the flue gas system
baffle valve. The adjustment time for relevant baffle can guarantee any device of absorption tower will not be
damaged without emergency cooling system.
1.3.3 FGD system is equipped with 100% emergency bypass flue. In normal operation, the baffle valve on
bypass flue is closed, and FGD system outlet baffle valve and booster fan inlet/outlet baffle are open. When
FGD system stops, the baffle valve on bypass flue is open, FGD system inlet/outlet baffle valve is closed, and
the flue gas directly enters the chimney to guarantee the main unit will not be affected in case of shutdown
and repair of desulfurization system.
1.3.4 The system is designed with GGH, which can efficiently decline absorption tower inlet flue gas
temperature, reduce flue gas-borne water in the tower, and increase outlet clean flue gas temperature and
reduce flue gas corrosion.
1.3.5 Simplified flow chart of flue gas system
Original flue gas from boiler→ original flue gas baffle→ booster fan→ absorption tower→ clean flue
gas baffle→ chimney
Original flue gas from boiler→ bypass flue gas baffle→ chimney
The flue gas system includes main devices: booster fan, original flue gas baffle valve, clean flue gas
baffle valve, bypass baffle valve, flue expansion joints and seal fan, etc.
1.4 SO2 absorption system
Each unit is equipped with one absorption tower. Adopt packed counter-flow absorption tower. The
tower is equipped with seawater distribution system, demister and packing; the seawater absorbs SO2 in flue
gas by once-through method. The fresh seawater enters from absorption tower upper par, the flue gas flows
through packing layer upwards from tower bottom, fully contacts with seawater, and SO2 in flue gas is
rapidly absorbed by seawater. The clean flue gas after desulfurization removes its water mist through
demister and drains from tower roof, and then enters GGH for heating. The acidic seawater after flue gas
cleaning is discharged from the tower bottom, and flows to seawater recovery system through drainage

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pipeline.
1.5 Seawater supply system
The desulfurization absorber drains water with condenser circulating cooling water, after pressurized
with seawater booster pump and directly supplies to desulfurization absorption tower. The reacted seawater is
discharged to seawater recovery system. Another part of condenser outlet circulating cooling water leads out
to seawater recovery system through drainage pipeline, mixed with desulfurized seawater in the seawater
recovery system. After the desulfurized draining water reaches the target, it is discharged into the sea from
circulating water outlet through open drainage channel of the power plant.
1.6 Seawater recovery system
1.6.1 Seawater recovery system includes aeration basin and aeration fan. The aeration basin is divided into
water distribution zone, aeration zone, emission zone and bypass zone.
1.6.2 A large quantity of fresh seawater from unit circulating water system siphon well enters water
distribution zone of aeration basin for water distribution, wherein, most of the seawater enters aeration zone
front-end, mixed with directly accessible desulfurized seawater, and a small part of fresh water is directly
discharged into emission zone through bypass zone. The mixed seawater is aerated during forward flow
process in aeration zone, and the aeration fan blows a large quantity of air through aeration diffusion device
(aerator) so as to create a large quantity of fine bubbles to make dissolved oxygen in seawater within aeration
basin saturated and oxidize labile sulfite into stable sulfate ion, and the carbonate CO32- and bicarbonate
HCO3- in seawater can react with H+ discharged from absorption tower to release CO2 through aeration so as
to meet the requirements on seawater emission standard and finally discharge back to the sea. The
desulfurized seawater realizes seawater PH value≥6.5, COD discharge value ≤6mg/l and dissolved oxygen
DO>3mg/l through aeration & oxidation to accomplish no-pollution discharge. .
1.7 Other auxiliary systems
1.7.1 FGD device GGH bypass baffle valve is equipped with electric actuator, and other valves (air valves)
under automatic control and remote operation are equipped with pneumatic actuator. The instrument
compressed air is supplied by main engine.
1.7.2 Adopt steam for heat exchanger component purging medium of flue gas heat exchanger. The steam
source is supplied by boiler purging steam system for main steam and auxiliary steam. The closed chilled
water system for desulfurization island leads from main engine closed chilled water, used for the cooling of
booster fan motor bearing and oil stations.
1.7.3 The desulfurization island is installed with independent process water system, with two-way water
source respectively from industrial water and industrial wastewater, and normal industrial wastewater
makeup water is used as flushing water for GGH and absorption tower demister.

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2. Equipment specifications
2.1 Flue gas desulfurization (FGD) system performance

2.1.1 Flue gas desulfurization (FGD) system inlet flue gas parameters
No. Item Unit Value (statement)
FGD inlet flue gas volume (standard state, wet basis,
1. Nm3/hour 2321035
BMCR)
2. FGD inlet flue gas temperature ℃ 122
3. FGD inlet flue gas pressure Pa 150
4. FGD inlet dust concentration mg/Nm3 148
FGD inlet flue gas components (design medium, standard state)
5. CO2 Vol-% 12.87
6. SO2 (dry state) vppm 481
7. SO3 (dray state) vppm 5
8. N2 Vol-% 76
9. O2 Vol-% 6.35
10. H2O Vol-% 4.73
2.1.2 Flue gas desulfurization (FGD) system supplied seawater parameter

1. Available seawater volume m3/h 100000
2. Seawater temperature ℃ 30—39.1
3. Seawater salinity psu 31.8
4. Seawater dissolved oxygen content mg/l 6.5
5. Seawater PH 8.34
2.1.3 Flue gas desulfurization (FGD) system performance requirements

1 Desulfurization efficiency % ≥ 90
2 Allowable load variation for FGD system % 70~100
3
3 SO2 maximum emission concentration mg/Nm 153
4 PH of draining water ≥6.5
5 Dissolved oxygen of draining water mg/l >3
6 Chemical oxygen demand (COD) of draining water mg/l ≤6
7 FGD outlet flue gas temperature ℃ ≥70

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2.2 Equipment specifications

Name Specifications Quantity
Pump type: vertical mixed-flow pump
Model: VMF1350-1180
Flow: 18900m3/h
Pump lift: 17m
Static head: 16.5m
Rotating speed: 493r/min
Maximum vibration amplitude: 4.5mm/s
Motor type: VSTC
Seawater booster pump 3 sets
Motor cooling mode: AAC
Motor voltage: 6600V
Motor frequency: 50Hz
Motor power: 1700Kw
No-load current: 78.8A
Full-load current: 193.1A
Starting current: 1062A
Motor rotating speed: 492r/min
Fan type: fixed-blade adjustable axial fan
Fan model: RAF45.5-22.4-1
Maximum flow: 1051.14m3/s
Maximum total pressure rise: 3960kPa
Booster fan 1 set per boiler
Maximum fan axle power: 4782kW
Fan rotating speed: 590r/min
Motor rotating speed: 590r/min
Motor nominal power: 5300 kW
Aeration fan Fan model: 2825A/460 6 sets
3
Flow: 34416m /h
Fan rotation speed: 2970r/min
Total pressure: 31200Pa
Fan power: 400KW
Motor model: YKK450-2TH
Power: 400KW
Frequency: 50Hz
Motor rotation speed: 2931 r/min
Rated voltage: 6600V
Rated current: 40.6A
Temperature rise: 70K
Heat exchanger Model: BR5-1.0-3HE
Heat exchange area: 31m2
Design pressure: cold side and hot side 1.0MPa
Design temperature: cold side and hot side 100℃

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Name Specifications Quantity

Boundary dimension: 1010*520*1500mm
Flue gas reheater Model: 32.5GVN450 1 set for each boiler
2
Heat exchange area (one side): 13494m
Total weight: 96.57T
Shell height: 1165mm
Master drive motor: 22KW variable frequency drive
Standby drive motor: 22KW variable frequency drive
Master motor reducing gear and primary inclined gear reducing
speed ratio: 5.429/1
Master motor reducing gear and primary worm gear reducing
speed ratio: 44/3
Master motor reducing gear and secondary worm gear reducing
speed ratio: 59/4
Standby motor reducing gear and primary inclined gear reducing
speed ratio: 5.429/1
Standby motor reducing gear and primary worm gear reducing
speed ratio: 44/3
Standby motor reducing gear and secondary worm gear reducing
speed ratio: 59/4
Rotor speed: 1.25r/min
Low pressure washing speed: 0.625r/min
Flow: 1500m3/h
GGH seal fan Fan static pressure rise: 8kPa 4 sets
Air temperature: +16.1~+39.4°C
Type: piston pump
Model: 3D2A
GGH HP water pump Axle power: 90KW 2 sets
Flow: 3.58 L/min
Maximum working pressure: 200bar
3. Maintenance and overhaul of flue gas desulfurization (FGD) system devices
FGD system device is divided into three levels of A, B, C,

Class A overhaul refers to the disassembly inspection and repair to FGD system in an all-round way to
maintain, restore and improve device performance.
Class B overhaul refers to the disassembly inspection and repair of some devices of FGD system which
have problems. According to assessment results of FGD device condition, class B overhaul is targeted to
implement parts of class A or regular rolling overhaul items.
Class C overhaul refers to focus on the FGD system for inspection, evaluation, repair and cleaning
according to wear, corrosion and aging laws of device. It can conduct some tasks, such as a small amount of
parts replacement, elimination of device defect, adjustment and the preventive test, and implement parts of
Page 6 of 71
class A and B or regular rolling overhaul items.

Regular overhaul refers to preventive repair of FGD system on the basis of time and pre-determine
overhaul modes according to the statistical regularity of device wear and aging, such as overhaul level,
overhaul interval, overhaul item and needed spare parts and materials.
Condition overhaul refers to the way to assess device condition and repair before failure occurrence
according to device condition information provided by condition monitoring and diagnosis technology of
FGD system.
Proactive overhaul refers to reform the congenital defect or frequent failure of device of FGD according
to the current device technical level and developing trend. Its purposes are to eliminate device defect,
improve technical performance and availability factor of device and implement overhaul mode combined
with the overhaul process.
Corrective overhaul refers to implement non-planned overhaul when FGD device has malfunctions or
other failures.
The following is the general overhaul and maintenance items and requirements of FGD system devices.
Please see delivery attached documentations for individual device about the overhaul and maintenance
requirements for specific device.
3.1 Overhaul and maintenance items of all levels
System Level C overhaul
Equipment name Level A overhaul item Level B overhaul item
classification item
1) Inspect abrasion of shell, liner 1) Eliminate the defects 1) Inspect filter screen
plate, blade and outlet guide vane, during equipment of oil cooler, clean it or
take records and replace impeller operation, inspect parts replace it.
when necessary. that are abnormal 2) Inspect oil level of
2) Inspect bearings in the main during operation and oil supply device and
bearing box and replace them replace them when inject oil when
when necessary. necessary, and necessary.
3) Inspect gearing and add eliminate the leakage at 3) Inspect pressures of
lubricating grease for damper sealing points. oil pump and oil
Flue gas system Booster fan shaft and gearing. 2) Sweep and inspect system, main bearing
4) Measure the clearance between fan’s hydraulic control box and blade
blade top and shell. apparatus, hub, blade, hydraulic control
5) Inspect and clear up surge flue gas channel and its apparatus.
probe. damper. Measure and 4) Inspect temperature
6) Inspect air leak of expansion inspect the abrasion of main bearing.
joint and shroud ring. degree of blade, guide 5) Inspect blockage of
7) Conduct strip inspection of oil vane, support and air oil filter screen and
pump in the oil station, replace flue and carry out replace it when
shaft seal and replace oil pump anti-abrasion or necessary.

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classification item
when abrasion is severe. replacement when 6) Inspect equipment
8) Inspect valves in the oil system necessary. abrasion.
and eliminate leakage points. 3) Inspect and clear the
9) Clear up oil tank in the oil oil system of
station and replace oil as per equipment, inspect
specific situation. shaft seal of oil pump
10) Carry out strip clear and and clean oil cooler.
inspection for cooler in the oil 4) Test oil quality in the
station and conduct air tight test. oil station and replace it
11) Perform blade flaw detection when necessary.
inspection. 5) Inspect whether
12) Perform motor bearing bush cooling water system is
inspection. unblocked.
13) Perform seal fan inspection. 6) Calibrate whether
14) Make signs and marks for actual angle of guide
equipment and equipment paint vane is consistent with
shall be complete and has no the angle on the index
peeling off phenomenon. dial.
1) Visual inspection. 1) Visual inspection. 1) Visual
2) Conduct thickness detection 2) Conduct inspection, repair the
for abrasion part and repair it thickness detection and damaged and crack
when necessary. re-construct them for positions.
3) Conduct electric spark abrasion part. 2) Visual
detection for crack and corrosive 3) Conduct electric inspection for abrasion
Anti-corrosion
parts and repair it when spark detection for part.
necessary. crack and corrosive
4) Conduct local hardness parts and re-construct
detection. them.
5) Conduct local bonding force
detection.
1) Inspect and adjust damper 1) Inspect and adjust 1) Conduct seal air
control apparatus and replace damper control hose inspection in the
damaged seal component. apparatus and replace seal fan system and
2) Inspect seal air hose and valves damaged seal replace rusted through
Damper valve and and replace them when necessary. component. seal air hose when
sealing system 3) Clean the soot formation on the 2) Conduct seal air necessary.
sealing fins of damper valves, hose inspection in the 2) Clean the soot
inspect sealing fins and replace seal fan system and formation on the
damaged ones. replace rusted through sealing fins of damper
4) Inspect opening time of seal air hose when valves.

Page 8 of 71

classification item
dampers and calibrate stroke. necessary. 3) Inspect opening
5) Conduct strip inspection for 3) Clean the soot time of dampers and
seal fan and replace bearings. formation on the stroke.
6) Inspect support bearings of sealing fins of damper
damper valves, replace damaged valves.
ones and re-lubricate them. 4) Inspect opening time
7) Inspect damper seal air inlet of dampers and stroke.
valve action and leakproofness.
1) Deal with the failure parts 1) Inspect and repair 1) Conduct tube
inside absorption tower anti-corrosion of inner leakage inspection for
comprehensively and conduct wall, support bean, strut absorption tower and
local replacement when necessary. members and spraying replace them when
2) Repair absorption tower wall layer. necessary.
and components when necessary 2) Inspect and repair 2) Wash, inspect and
and carry out anti-corrosion nozzles and test them. clean sundries on the
treatment again. 3) Replace damaged or packing layer.
3) Inspect and clean nozzles and failure parts inside the 3) Repair or handle
Sulfur dioxide conduct pulverization inspection tower. corrosive wear parts
absorption Absorption tower for nozzles. 4) Wash, inspectand inside the tower.
system 4) Inspect and clean the sundries clean the sundries on the
on the packing layer. packing layer.
5) Clean the sundries and soot
formation on the absorption tower
bottom.
6) Inspect connecting bolt of
seawater distribution tube.
7) Inspect packing layer support
grating, repair and replenish
packing if packing is lost.
1) Inspect whether demister is 1) Inspect whether 1) Inspect whether
collapsed or damaged. demister is collapsed or demister is collapsed
2) Inspect whether surfaces of damaged. or damaged.
Demister demister components are clean. 2) Inspect whether 2) Inspect whether
surfaces of demister surfaces of demister
components are clean. components are clean.
1) Dismantle coupler and 1) Dismantle coupler 1) Dismantle coupler

Seawater supply
Seawater booster inspect coupler bolt and leaf and inspect coupler bolt and inspect coupler
and drainage
pump spring. and leaf spring. bolt and leaf spring.
system
2) Dismantle pump end cover 2) Dismantle pump end 2) Sweep and inspect

Page 9 of 71

classification item
and remove pump head. cover and remove pump inlet and outlet glass
3) Inspect shaft sleeve, head. steel tube and rubber
mechanical seal, pump shell and 3) Sweep and inspect expansion joint and
impeller. inlet and outlet glass wash inlet filter
4) Sweep and inspect inlet and steel tube and rubber screen.
outlet pipeline and expansion expansion joint and 3) Calibrate pump and
joint and wash inlet filter screen. wash inlet filter screen. motor center.
5) Inspect parts of mechanical 4) Inspect impeller
seal and bearing and replace abrasion and replace it
mechanical seal. as per abrasion
6) Measure clearances of parts condition.
and inspect pump shaft (including 5) Calibrate pump and
shaft curve and flutter motor center.
measurement).
7) Inspect and replace over
corrosive wear pump parts.
8) Calibrate pump and motor
center.
1) Dismantle electric butterfly Inspect whether valve Inspect whether valve
valve entirety, inspect and clean leak test and switching leak test and switching
Electric butterfly
the valve body inner cavity and test are normal, or test are normal, or
valve at the pump
flange junction surface. perform Level A perform Level A
outlet
2) Inspect and replace valve shaft overhaul process overhaul process
seal ring (or packing). procedure. procedure.
1) Inspect blockage condition of 1) Inspect blockage and Inspect blockage and
filter screen and clean bulkhead of damage condition of damage condition of
filter screen. filter screen and clean filter screen and clean
2) Inspect damage condition of bulkhead of filter bulkhead of filter
filter screen and replace it if screen. screen.
Filter screen
necessary. 2) Inspect corrosion
3) Inspect corrosion condition of condition of filter screen
filter screen driving medium and fasteners to handle or
fasteners to handle or replace replace them.
them.
1) Inspect and clean the sundries 1) Inspect and clean
in the seawater ditches. seawater pipes and
Seawater supply
2) Inspect leakproofness of channels.
and drainage ditch
seawater ditches and handle
leakage parts.
Seawater Aeration fan 1) Inspect and repair damaged 1) Inspect and repair 1) Inspect and clean the

Page 10 of 71

classification item
recovery system shell, blade and impeller and damaged shell, blade sundries attached on
replace impeller parts when and impeller and replace the blade.
necessary. impeller parts when 2) Inspect and repair
2) Clean silencer. necessary. inlet damper, blade and
3) Inspect and repair rotor, bearing 2) Clean silencer. gearing.
and bearing box and replace 3) Inspect and repair 3) Clean silencer.
bearing parts when necessary. rotor, bearing and 4) Inspect and adjust
4) Replace lubricating oil in the bearing box and replace drive device.
bearing box. bearing parts when
5) Inspect and adjust drive device. necessary.
6) Calibrate balance of fan 4) Replace lubricating
impeller when necessary. oil in the bearing box.
5) Inspect and adjust
drive device.
1) Inspect and clean aeration tank 1) Inspect and clean 1) Inspect aeration
and repair inner wall aeration tank and repair tank inner wall
anti-corrosion layer. inner wall anti-corrosion layer.
Aeration tank 2) Inspect, clean and dredge anti-corrosion layer. 2) Inspect aeration
aeration pipeline, valves and 2) Inspect and clean pipeline, valves and
nozzles. aeration pipeline, valves nozzles.
and nozzles.
3.2 Main equipment maintenance process and quality requirement

Equipment Maintenance
Main process points Quality requirements
name contents
1) Coupler should be intact and have no crack and
rod pin hole should be smooth and have no burr.
1) Inspect coupler. 2) Couplers should be smooth and have no loose
2) Inspect the joint between and should be closely fitted.
Inspect and adjust
coupler and journal. 3) There are no crack and deformation; pressure
coupler.
3) Inspect coupler bolt. plate should be smooth and bolt should be even.
4) Coupler alignment. 4) Clearance is no more than 5 mm; radial missing
is no more than 0.05 mm and axial missing is no
Booster fan
more than 0.05 mm.
1) Inspect bearing alloy surface. 1)Alloy surface should have no crack, sand hole,
2)Adjust clearances of various interlayer or unshelled and other defects.
Inspect bearing and
parts. 2) It should meet factory’s requirements.
bearing box.
3) Bearing box appearance 3) It should be clean inside and outside the box
inspection. and there are no oil stains and other sundries.
1) 1) Appearance inspection 1) There are no crack, deformation and other
Inspect impeller.
and corrosion inspection. defects.

Page 11 of 71
name contents
2) 2) Impeller rotating flutter 2) It should meet factory’s requirements
and static balance inspection and 3) There are no corrosion, pit and so on.
measure unbalance weight.
1) 3) Inspect blade apex
clearance, degree of balance and
so on.
1)Inspect surfaces of main axle
1) There are no crack and other defects and journal
and journal.
Inspect and adjust should have no groove.
2) Inspect main axle straightness
main axle. 2) Straightness is 0.05 mm and cylindricity
and journal cylindricity
tolerance is 0.04 mm.
tolerance.
1) Inspect oil pump and coupler
1) Cooling water system various pipes and gates
and change bearing and shaft
have no leakage.
seal rubber ring.
2) Fuel system various pipe line joints have no
2) Clear fuel tank bottom dirt
Lube oil station leakage phenomenon.
and change fuel.
maintenance 3) Water pressure is 0.5Mpa and there is no
3) Oil cooler water pressure leak
leakage when oil cooler operates for 30 minutes.
finding.
4) Oil station outlet working pressure is no lower
4) Clear fuel filters strainer
than 2.5Mpa.
element and magnetic filter.
1) Impeller surface should have no corrosion,
1) 1) Inspect impeller surface. deformation and crack and impeller surface is
Overhaul impeller
2) 2) Inspect sealing fin clean.
and sealing fin.
deformability. 2) Sealing fin has no obvious deformation and
change it if there is serious gas leakage part.
1) Inspect sealing air pipe
1) There are no sundries, corrosion and leakage in
corrosion and connector
Overhaul sealing the pipe and pipe is clear.
connection and drain pipe.
air device. 2) Sealing fan can make sure wind pressure and
2) Inspect and overhaul sealing
rotating wind pressure.
fan device.
1) Inspect whether bearing has
mechanical damage. 1) Bearing has no corrosion and crack.
Overhaul bearing.
2) Inspect whether bearing block 2) Bearing block has no crack and it is well fixed.
has displacement or crack.
Inspect whether worm gear,
Damper Worm gear and worm are intact and have no
Overhaul worm worm and box body have
corrosion and lube oil does not go bad and oil
gear case. mechanical damage and change
level is normal.
lube oil.
Overhaul baffle Inspect whether baffle Baffle connecting rod should have no curve and
connecting connecting rod has deformation deformation, firm connection, can open and close

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name contents
mechanism. or curve. First inspect each flexibly and it reaches full closing in 00 and full
rotating and then install opening in 900 .
transmission connecting rod and
inspect whole baffle.
1) Inspect and change shaft seal 1) Shaft seal should be intact and have no
Baffle shaft seal packing. corrosion and leakage.
maintenance 2) Inspect and adjust oil seal 2) Shaft seal press cover should be clean and have
press cover. no crack.
1) Inspect baffle body action 1) Inspect baffle action is smooth and has no
situation. obstruction, abnormal sound and noise and action
Baffle body
2) Inspect baffle body and is in place.
maintenance
sealing fin abrasion and 2) Inspect baffle is in tight closure and has no
corrosion situation. leakage and no breakage.
1) Surface and weld joint are neat and have no
1) Impeller and blade surface
crack.
inspection.
2) Impeller and main axle connecting key must not
2) Main axle journal and
have loose sense and key top clearance is
installation inspection.
Inspect impeller 0.3-0.5mm.
3) Impeller rotating flutter and
and main axle 3) Impeller, main axle fixed ring and tightened
static balance degree inspection.
maintenance. ring must not have loose sense.
4) Impeller, main axle fixed ring
4) Macro axis levelness error is no more than
and tightened ring inspection.
0.04mm/m.
5) Mule and impeller clearance
5) Mule and impeller are joined: axial clearance is
inspection.
3-5mm.
1) Wind shell, support surface and weld joint are
neat and have no crack.
1) Wind shell and support
Aeration fan Chassis mule 2) Mule installation is firm and mule seal ring has
inspection.
maintenance. no deformation.
2) Mule inspection.
3) Mule and impeller clearance meet factory’s
requirements.
1) Inspect baffle and actuator 1) Baffle should keep switch working well and
Inlet baffle opening. switch angle indicates correctly.
maintenance. 2) Inspect and change baffle 2) Baffle and part installation are intact and shaft
shaft seal packing. seal is precise.
1) Calibrate motor magnetic

1) Coupler radial missing is ≤0.05mm and axial
Calibrate coupler center.
missing is ≤0.05mm.
center and find 2) Coupler calibration and
2) Foot pads are no more than 3 pieces.
balance. connection.
3) Fan vibration value meets factory’s
3) Find dynamic balance.
requirements.

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name contents
1) Inspect oil pump and coupler
1) Cooling water system various pipes and gates
and change bearing and shaft
have no leakage.
seal rubber ring.
2) Fuel system various pipe line joints have no
3) Fuel tank bottom dirt
Lube oil station leakage phenomenon.
clearance and change fuel.
maintenance. 3) Water pressure is 0.5Mpa and there is no
3) Oil cooler water pressure leak
leakage when oil cooler operates for 30 minutes.
finding.
4) Oil station outlet working pressure is normal
4) Clear fuel filters strainer
and filter differential pressure is normal.
element and magnetic filter.
Scaling, soot formation and
There is no large area scaling, soot formation or
deposition inspection and
blockage and no dust is locally accumulated.
clearance.
Tower internal
1) Mend corrosion and abrasion 1) Undergo erosion resistant treatment after
parts maintenance.
support. finishing repairing support.
2) Packing inspection and 2) Packing top is neat and has no sundries and
clearance. filling amount meets design requirements
Tower wall and
erosion resistant
Tower wall leakage inspection. Undergo handling and adopt erosion resistant
coating
measures for leakage parts according to location.
maintenance.
Inlet and outlet Tower wall lining erosion resistance coating
Tower wall erosion resistant
Absorption flue, tower wall should not have crack, bubbling, peeling off and
coating inspection and flaw
tower and tower internal other phenomena. Repair damaged erosion
detection.
part maintenance. resistance coating.
1) Inspect pipe flange and
1) Flange and connecting pieces are intact and
Seawater pipe connecting pieces.
have no leakage.
inspection. 2) Pipe internal inspection and
2) There are no sundries in the pipe.
clearance.
1) Nozzle inspection is
Spray nozzle 1) Nozzle installation is firm and has no blockage.
unblocked.
maintenance. 2) Spray effect is good.
2) Nozzle spray test.
1) Defogger inspection and 1) There is no breakage and falling and defogger
Defog components mending. components’ installation is intact.
maintenance. 2) Supporting framework 2) Supporting framework is intact and there is no
inspection and mending. fracture and damage.
Impeller and axle
Inspect shaking degree. Shaking degree is ≤0.05 ㎜.
sleeve
Seawater
1) Inspect coupler. 1) Coupler and middle nipple should be complete
booster pump
Inspect coupler. 2) Inspect the joint between and have no crack and no deformation, whose
coupler and journal. surface is bright and clean, and coupler and axle

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name contents
3) Inspect coupler bolt. firmly join and have no loose.
2) Connecting bolt should have no curve and
deformation; bolt is intact; gasket, spring cushion
and nut should be complete.
3) Coupler and axle joint is H7/K6.
4) Joint among keys must not have loose sense and
key top clearance is 0.3-0.5mm.
Various parts surfaces should be neat, bright and
All parts Surface inspection. clean, no damage and no defect and castings have
no crack, bubble and other defects.
Axle surface has no crack, corrosion, groove mark
Axle Inspect flexibility. and other undesirable phenomena and axle shaking
degree is ≤0.05mm.
Impeller Inspect gourd ladle skewness. Gourd ladle skewness is ≤0.05 ㎜.
Seal ring and Radial clearance is 0.35-0.45mm, axial clearance
impeller Inspect fit clearance. is 1.5-2.0mm and tightening force is 0.03-0.05mm.
1) Mechanical seal shaft sleeve has no crack and
sgraffito phenomena and fit clearance with axle is
≤0.07mm.
2) Mechanical seal working compression amount
is 50%-70% of total compression amount.
Inspect and change mechanical
Mechanical seal 3) Mechanical seal has no eccentric wear, crack
seal.
and other phenomena; moving ring spring and
supporting framework are good and have no jam;
moving and static ring surfaces are bright and
clean, which have no crack, scratch, rusty spot or
groove.
Pump body sealing Surface is neat, bright and clean, has no defect,
Inspect joint surface integrity.
flange. intact and has no leakage.
1) Axial clearance is 2.5-5mm and radial clearance
between impeller inlet and pump shell is 0.70mm.
Impeller and pump 1) Installation clearance
2) Rotor disc flexibly move and has no jamming.
shell inspection.
3) Radial shaking degree is ≤0.10mm at impeller
seal ring.
1) Coupler excircle deviation is ≤0.1mm; coupler
end face deviation is ≤0.06mm.
Calibrate coupler Coupler calibration and
2) Foot pads are no more than 3 pieces.
center. connection.
3) Water pump vibration value meets factory’s
requirements.

Page 15 of 71

Page 16 of 71
4. Dirt catcher equipment maintenance and overhauling
4.1 Electric precipitator equipment overview

4.1.1 Operating principle
When energizing HP DC electricity for the discharge electrode in the electric precipitator, gas near this
electrode will produce a large amount of positive ions and electrons due to ionization. Dust in the flue gas
will be charged in the electric field when air-laden flue gas enters electric field, charged dust moves to the
direction with reverse polarity electrode under the effect of electric field force, and dust is adsorbed on the
polar plate or polar line when achieving at polar plate or polar line. Dust peels off and falls into dust hopper
in favor of vibrating effect when dust reaches to certain thickness.
4.1.2 Structure
Electrostatic precipitator is mainly composed of shell body, air flow distribution device, flue gas tank
system, dust collection electrode system, corona electrode system, cathode vibrating device, anode vibrating
device, dust hopper, dust unloading device, gasification system, HP/LP power supply device and auxiliary
system.
4.1.3 Electric precipitator equipment overview
4.1.3.1 Vinh Tan Phase II 2x622MW unit flue gas dedusting system uses electric precipitator. Each boiler is
equipped with two electrostatic precipitators and electric precipitator is double-room-four-electric field
structure. Equip 16 dust hoppers for each precipitator. Equip with heating system and its gasification system
for dust hopper and arrange dust unloading device for dust hopper. Equip with a set HP silicon rectifying
equipment for each electric field and equip with HP separating switch cabinet.
4.1.3.2 Flue gas from boiler air preheater enters interior of electric precipitator through electric precipitator
inlet air flow distribution plate, passes through I, II, III and IV electric filed in sequence, to make dust be
absorbed on the anode plate and cathode ray through HP static dust collection, and make dust fall into dust
hoppers through cathode and anode vibrating device. Discharge the dust through dust unloading device. Flue
gas from electric fields brings in desulfurization absorption tower to remove SO2 in the flue gas by
desulfurization booster fan, and then emit the flue gas to the atmosphere.
4.2 Equipment specification
4.2.1 Electric precipitator (it’s the data of one precipitator if no specified mark)
Item Feature and specification Unit Remarks
Model 2FAA4×4.5m-2×15.2m-15m
Electric precipitator
Electrostatic 2 Set
number for each boiler
precipitator
Flue gas volume 3281723.2 m³/h
Dry flue gas volume 2144573 Nm³/h

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Precipitator inlet flue gas
125.1 ℃
temperature
Inlet dust volume of each
44722 mg/ Nm³
precipitator
Main body resistance ＜200 Pa
Main body air leakage
＜2 %
rate
Guaranteed efficiency ≥99.69 %
Outlet dust concentration ≤148 mg/ Nm³
Number of channels 38 Set
Effective sectional area 456 m²
Room number/ electric
2/4
field number
Effective length of a
4.5 m
electric field
Total effective length of
18 m
electric field
Specific collection area 90.04 m2/m3/s
Migration velocity 7.22 cm/min
Flue gas retention time 18.01 s
Space between the same
400 mm
electrodes
Anode plate form 480C
Anode plate specification
(height, width and 1500*480*1.5 mm
thickness)
Anode plate block
number of a single 702
electric field
Anode plate effective area 41040 m2
Anode vibrating form Side mechanica. vibration
Anode minimum
vibrating accelerated 150g
speed
Anode vibrating device
8 Set
number
Cathode ray mode RSB
Total length of cathode
61560 m
ray
Cathode ray vibrating
Side mechanica. vibration
mode
Page 18 of 71

Cathode minimum
vibrating accelerated 50g
speed
Cathode vibrating device
8 Set
number
Dust hopper number
equipped for each 16
precipitator
4.2.1 Auxiliary equipment specifications (it is the data of one precipitator if no specified mark.)
Equipment Parameter Quantity
Rectifier transformer Model: GGAj-2.0A/72KV 8 sets
AC input: rated voltage: 400V (effective value)
rated current: 540A (effective value)
Frequency: 50/60Hz
DC output: rated voltage: 72KV (average value)
rated current: 2.0A (average value)
HP isolating switch Model: FTTB 8 sets
Rated voltage: 72KV
Rated current: 3A
Cathode vibration Reducer model: XLED63-595-0.37KW 8 sets
Reducer form: cycloidal-pin wheel reducer
Motor model: Y27124
Rotating speed: 1440r/min
Power: 0.37KW
Rated voltage: 400V
Frequency: 50Hz
Rated current: 1.14A
4.3 Safety tips (precautions)

Electric precipitator is the dust collection device to deal with dust in high temperature flue gas from
boiler,which comes from coal combustion and is harmful to human health. Before someone entering the
electric-bag composite dust collector, he must receive strict approval process and reliable safety protective
measures. Everyone before entering the dust collector must read and completely understand the safety
regulations, and examine the implementation of all the safety measures.
Special attention!
 Power supply device of electric precipitator and cathode system carry dangerous and fatal high
voltage.
 As most of electric precipitators run in the negative pressure state, accidents would happen if any

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door opening isn’t closed.

 As current in the main circuit of power supply device in the electrostatic precipitation area of
electric precipitator is relatively high, reliable contact of each joint circuit shall be checked to avoid heating
or fire disaster resulting from bad contact.
 Safety work shall be guaranteed during the using of electric precipitator, including personal and
device safety, namely necessary safety device, and there are requirements about safe operation on
maintenance management.
4.3.1 Pay attention to the following on safety device:
4.3.1.1 Metal shell of the electric-bag composite dust collector,rebar of concrete foundation, electrode
board in electric field, scarfskin and cable head of various high voltage cables and each control steel structure
all shall be well-grounded, and the ground resistance shall be kept under 1 Ohm.
4.3.1.2 There shall be interlocking switch on high voltage transformer chamber and high voltage rectifier
chamber,to cut off the power of high voltage device automatically when the door is opened.
4.3.1.3 There shall be warning boards and warning signs around high voltage cable,cable head and high
voltage rectifier.
4.3.2 What shall be done on safety:
4.3.2.1 Each device of the electric-bag composite dust collector shall be checked before starting up, to
ensure the device in normal working, no one working in dust collector, and each manhole turned off already
before starting up.
4.3.2.2 Rapping apparatus shall be turned on first before supplying high voltage to electric field, and after
cutting off power to electric field ,rapping apparatus shall run more than half an hour, trying to shake off dust
storing on the electrode.
4.3.2.3 The electric-bag composite dust collector which has cooled shall be preheated by flue gas, to make
the temperature gradually increase, and voltage shall be supplied after the temperature of electric
field(including electrode board,electrode line and so on) going up and no cold condensation phenomenon.
4.3.3.4 Ash hopper level indicator has been installed at the head of the ash hopper, and it shall sound a
warning signal when there is a high level. However, pay special attention in case of failure happening to level
indicator and causing dust accumulation, to avoid personal injury and device damage or environmental
pollution.
4.4 Maintenance items
4.4.1 Remove ash in the internal of electric field.
4.4.2 Inspect anode plate and cathode vibration device.
4.4.3 Inspect cathode large and small framework and cathode vibration device.
4.4.4 Inspect electric precipitator shell body large dust hopper, outlet and inlet gland, top, man hole door

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and flue.
4.4.5 Inspect air deflector, air flow distributor and back plate.
4.4.6 Inspect dust hopper heating device and top insulator compartment heating device.
4.4.7 Inspect dust hopper gasification wind device.
4.5 Equipment parts maintenance methods and precautions
4.5.1 Remove ash in the internal of electric field.
1 Inspection before ash removal:
 Inspect anode plate and cathode line soot formation situation, analyze soot formation causes and
make technical records.
 Inspect air flow distributor and trough plate soot formation situation, analyze soot formation causes
and make technical records.
 Inspect polar plate deviation situation and inter-electrode distance macroscopic inspection.
2 Ash removals:
 Electric field inner top and insulating sleeve protective barrel.
 Anode plate and cathode large and small framework and polar line.
 Vibrating part.
 Inlet air deflector, air flow distributor, trough plate and back plate
 Inlet and outlet flue, outlet air flow distributor, trough plate and dust hopper.
 Remove ashes in the following order: from top to down and from inlet to outlet, and do not drop
ash removal instruments.
 Inner electric field and dust hopper.
 When possible, dry it with hot wind after flushing ashes with water.
4.5.2 Anode plate device maintenance
1 Inspect anode plate deformation, abrasion and its hanger structure situation.
2 The datum of each electric field is anode plate row whose middle part is relatively flat and the
homopolar distance is measured with polar distance pallet tools. Spacing measurement should be at the outlet
and inlet position of each row of polar plate. The measurement is along three points of up, middle and down
on the polar plate height, and each large and small repair measurement should be at the same position and
make the records.
3 When the homopolar distance exceeds the manufacturers’ specifications, adjust the deformative polar
plate. For the deformative polar plates on running, which have been early found and which cannot be
eliminated with adjustment methods, prepare for unroofing before maintenance and change the whole row of
polar plate on maintenance.
4 When dies holder deviates, limit it according to requirements and leave activity gap in accordance with

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design specifications.
5 Inspect polar plate sinking situation and if it sinks inspect polar plate punch holder fixed pin or
concave and convex sets.
6 Inspect die holder (polar plate) trip rod deformative situation, bearing anvil head abrasive situation,
whether rivets or bolts for fixing are loose, inspect vibrating center and adjust it if necessary (it goes after
anode plate row and gear device maintenance).
7 Inspect anode plate belt and fixed screw should not be loose.
4.5.3 Cathode large and small framework device maintenance
1 Insulator compartment and insulating sleeve protective barrel maintenance
 Inspect bearing insulator crosstie deformative and horizontal situation; inspect results of bearing
insulators insulating sleeve according to electric maintenance; when needing to change it, mechanical parts
are coordinated to make fixing measurements of cathode large framework. When electric changes insulating
sleeves, pay attention to plugging around insulating pipe bottom with asbestos rope to avoid leaking wind.
 Inspect protective barrel corrosion and concentricity. When changing protective barrel, after
making firm fixation measurements between large framework and inwall, boom bolt exposed length and
relative position size, loose boom top large bolt, remove boom and penetrate protective barrel. Boom takes its
place, find protective barrel center and concentricity according to boom center and fix protective barrel.
Demolish large framework temporary fixation measurements, calibrate this large framework height and
horizontal position and pay attention to insulator crosstie levelness.
2 Cathode large and small framework maintenance
 Overhaul large framework levelness and verticality and shell body inner wall relative size should
comply with the design requirements.
 Inspect large framework deformation situation.
 If large framework horizontal direction needs to adjust, conduct it with changing insulator,
insulating sleeve or protective barrel; if adjusting it along, adjust it after jacking it with lifting jack.
 Inspect up down small framework connecting structure and small framework fixing clamps and
first adjust it if framework tube locally deforms.
 Each up down framework measures cathode small framework homopolar distance at two points,
which the same as anode plate row. When it exceeds specifications and has deviation, adjust it with fixation
clamp for trimming.
 When adjusting cathode small framework, conduct it along with measuring heteropolar distance,
finally make sure heteropolar distance is within prescribed limit and adjust cathode small framework based
on anode.
3 Cathode lines maintenance

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 Inspect polar line and small framework connecting plate snap or screw dropping situation.
 Inspect polar line discharge point dust, electric corrosion and “dropping sting” situation.
 When polar line in middle location of framework cannot be trimmed or changed, which influences
spacing, cut it.
 When cutting polar lines, pay attention not to damaging nearby polar lines.
4.5.4 Vibrating device
 Inspect vibrating anvil and sleeve intact, no fracture and breakage.
 Inspect vibrating anvil uplifted height and make records.
4.5.5 Air deflector, air flow distributor and back plate
1 Air deflector:
 Inspect abrasive situation.
 Inspect welding fixation situation.
 Inspect guide direction, angle and air flow distributor distance, which meet the requirements of
manufacturers.
2 Air flow distributors:
 Inspect connecting fixing clamp splint, loose dropping and screw abrasive situation and spot weld
when changing new screws.
 Fixed angle steel inspection should not swing; inspect upper hang air flow distributor U-steel and
screw corrosive situation.
 Inspect distribution plate tapping abrasive situation and distribution plate glancing flatness; when
tapping is abrasive, change it and adjust it when deforming.
 Distribution plate bottom and inlet gland inner wall spacing should conform to design
requirements.
3 Back plate;
 Inspect back plate soot formation, abrasive deformation and corrosive situation on the top two sides
and bottom of electric field. Spacing to polar plate conforms to design requirements.
 Inspect dust hopper back plate deformation situation and mobile back plate should be flexible.
4.5.6 Shell body, dust hopper, outlet and inlet gland, man hole door and flue
1 Shell body and dust hopper
 Inspect inner wall corrosion situation.
 Inspect dust hopper and inner shell body support abrasion and fixation situation.
 Dust hopper flange joint surface wind leakage situation inspection and leaking stoppage.
 When there are convex collapse and deformation on the inner wallboard of shell body, adjust it to
keep straight and avoid causing vortex.

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 Soot formation and corrosive situation inspection on top seal plate of electric field.
 Grey-headed outer steam heating device ring-shape pipe corrosive and leaking inspection and valve
and drain valve maintenance.
2 Outlet and inlet gland:
 Inner wall abrasion and corrosion situation inspection.
 Inner wall and support corrosion and abrasion inspection.
 Shell outlet and inlet flue flange joint surface air leakage inspection and handling.
 Concave collapse mending and reinforcement.
3 Man hole door maintenance:
 Through the maintenance, switch is flexible and jackscrew and handle are repaired.
 Man hole door joint surface is firm and does not leak wind; sealing packing is changed and
trimmed.
 Inner wall corrosion situation inspection.
 When man hole door and HP electric supply device have latching, coordinate electrical
maintenance and conduct it.
4 Defogger top cap and insulator compartment box body;
 Deformation top cap trimming.
 When boxing up, joint surface fills sealing gasket.
 Rainwater catch basin and sewer pipe maintenance.
 Inspect insulator compartment inner wall stringency and handle it if there are bulges.
5 Flue maintenance is the same as that of outlet and inlet gland maintenance and inspect expansion joint
abrasive and corrosion and flange joint surface stringency.
6 After overhauling, whole electric precipitator including insulator compartment insulation should trim,
which conforms to design requirements and mop it.
7 Electric field internal aisle maintenance
4.5.7 Local tiding
1 Stairs, platform and handrail trimming and mopping.
2 Signboards trimming and completion.
3 Ash groove clearance and trench covers are spread in order.
4 After maintenance, clear local sundries and detachable parts, useful parts are conserved according to
requirements and are piled neatly.
4.6 Acceptance, test run, test and summary
4.6.1 Quality acceptance
Do quality inspection and acceptance for ensuring maintenance quality. Quality inspection combines

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maintainer self-checking, mutual inspection and inspection personnel checking; after inspection personnel
finish each maintenance, according to quality standard, first after self-check is qualified and make technical
records and then send it to inspection personnel acceptance.
4.6.2 Test run and test
1 After electric precipitator maintenance and before test run, inspection personnel should do disclosure
to operating crew the following items: main maintenance items, equipment system improved transaction and
changing information, residual defects after maintenance and so on. During test run and test, relative
maintenance operating crew together inspect equipment technical conditions and operating situations.
2 On the condition of finishing LP electric maintenance and power transmission, after vibrating device
maintenance and finishing completion formalities, conduct test run and vibrating center verification.
3 After finishing electric field internal work and clearing sundries in dust hopper, conduct ash conveying
device test run.
4 Change more than 1/3 of air flow distributors, air deflector and parts concentrated, but if it is less than
1/3, conduct air flow distribution test.
5 Do HP and LP electric equipment protection, faults warning and signal monitoring test.
6 Do insulation sleeve and dust hopper heating device tests.
7 If necessary, do electric precipitator body and outlet and inlet gland leakage test.
8 After overhauling, conduct electric precipitator dust collection efficiency measurement under rated
load.
9 After electric precipitator overhauling and small repair, do cold no-load VA boosters tests.
4.6.3 Maintenance summary
1 After electric precipitator overhauling, organize relative personnel conscientiously summarize
experience, affirm achievements, discover disparity and continuously improve maintenance quality and
technological level.
2 After maintenance for one week, finish maintenance summary report (including equipment technical
records and test reports).
3 Equipment technical records are the important link of straightening equipment management and
technical management, so reserve them as technical files.
4.7 General fault and handling methods during electric precipitator operation
General fault and handling method during electric precipitator operation
No. Fault phenomena Main causes Handling methods
Control cabinet air 1.Defogger has foreign matter causing second 1. Clear foreign matter.
switches trip or trip level short circuit. 2. Cut off break line and take out cast.
1
again after 2.Discharge electrode fracture or internal parts 3. Repair level indicator and exclude soot
switching on. falling causing short circuit. formation.

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3. Level indicator is out of order and dust hopper 4. Clear soot formation and wipe
ash level rising causing discharging polar to insulator.
ground short circuit. 5. Change heating element and repair
4. Because of soot formation, discharge electrode insulation.
insulators produce creeping discharge or even 6. Inspect protection system.
break down.
5. Insulator heating elements are out of order or
insulations are not good, which makes insulator
post surface condensation and insulating property
degradation causing flashover.
6. Low voltage tripping or over current and over
voltage protection malfunction.
1. Smoke temperature is lower than dew point
temperature, which causes insulating property
reduces and produces serious flashover in low
Operating voltage
voltage. 1. Adjust boiler combustion conditions
is low, current is
2. Vibrating mechanism is out of order and polar and increase smoke temperature.
very small, or
plate and polar line have serious soot formation 2. Fix vibrating failure parts.
2 voltage increasing
which causes breakdown and voltage reducing. 3. Clear soot formation and fix
produces serious
3. Discharge electrode vibrates porcelain shaft, insulation.
flashover and trips.
PTEF guard place sealing is not firm and
insulation is not good, which makes soot
formation and produces creeping discharge.
1. Coal types change, dust specific resistance
Voltage is normal
becomes larger or dust density is too high, which
value or very high, 1. Smoke hardening and tempering and
causes corona closure.
3 current is very transform dust catcher.
2. HP loop is not good, for example damping
small or ammeter 2. Change damping resistance.
resistance is burnt out, which causes high-voltage
has no indication.
silicon rectifier transformer open.
1. HP parts insulation is not good. 1. Measure insulation resistance with
2. Spacing between discharge electrode and dust megohm meter, improve insulation
collecting polar becomes small. situation or change damaged insulation
3. There are foreign matters in the electric field. parts.
Voltage is low and
4. Discharge electrode porcelain shaft chamber 2. Adjust polar distance.
4 secondary current is
insulation parts temperatures are too low, which 3. Clear foreign matter.
too large.
causes insulation property reduces. 4. Inspect electric heater and wind
5. Cable or end box insulation is seriously leakage and clear soot formation.
damaged and current is leaked. 5. Improve cable and end box insulation.
6. Back corona phenomenon occurs. 6. Refer to “fault 20”.
Secondary ammeter 1. Discharge electrode breaks causing dipolar 1. Cut off discharge electrode broken
5
indicates limit short circuit. lines.

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values and 2. There are metal foreign matters in electric 2. Clear foreign matters.
secondary voltage field. 3. Fix or change damaged cable and end
is near zero. 3. HP cable or cable end box has short circuit to box.
earth. 4. Fix or change porcelain bottle.
4. Insulation porcelain bottle is damaged and has
short circuit to earth.
Secondary ammeter 1. Discharge electrode frameworks vibrate.
1. Eliminate framework vibration.
6 pointer periodically 2. After discharge electrode lines are broken off,
2. Cut off residual line segments.
swings. residual line segments swing on the framework.
1. Discharge electrodes deform.
Secondary ammeter
2. Dust particle adheres to polar plate or polar 1. Eliminate deformations.
7 pointer irregularly
causing inter-electrode distance becomes small 2. Vibrate and fall soot formation.
swings.
and producing electric spark.
Secondary ammeter 1. Make sure breakdown parts and fix
1. HP cable breakdowns to earth.
8 pointer violently them.
2. Electrode bending causes partial short circuit.
vibrates. 2. Calibrate curved electrodes.
1. Polar plate or polar has too much soot
formation. 1. Clear soot formation, inspect vibrating
Secondary voltage
2. Discharge electrode or dust collecting system and fix fault parts.
is normal and
9 electrode vibrating device does not open or is 2. Start or fix vibrating device.
secondary current is
partial out of order. 3. Clear soot formation and inspect
very small.
3. Corona lines are loose and discharging is not vibrating system.
good.
Secondary voltage
1. Paralleled with secondary ammeter protector is 1. Change protector.
and primary current
broken down. 2. Make sure broken lines parts and
10 are normal and
2. Current measurement system breakdowns. change them.
secondary ammeter
3. Ammeter pointer is jammed. 3. Fix or change ammeter.
has no reading.
1. Discharge electrode breakdowns but it does not
1. Cut off broken lines.
occur short circuit yet.
2. Relocate dust collecting electrode row
2. Dust collecting electrode plate row locating pin
plate and firmly weld locating pins.
Voltage suddenly cracks and plate row shifts.
13 3. Inspect electric heater and insulator
reduces sharply. 3. Discharge electrode vibrating porcelain shaft
compartment wind leakage situation and
chamber PTEF guard has soot formation and dew
trouble shooting.
formation.
4. Readjust and fix shifting framework.
4. Discharge electrode small framework shifts.
1. Repair insulation.
Inlet and outlet
2. Change sealing packing of manhole
smoke differential 1. Insulating layer falls off.
14 door and other leaking wind places,
temperature is 2. Wind leakage is serious.
repair welding shell body loose welding
large.
or cracking parts.

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1. Ash hole is blocked by foreign matter. 1. Take out of foreign matters.
15 Hod does not 2. Form dew because of ash too low temperature 2. Inspect dust hopper heating system and
unload ash. and form lump. make sure normal operation.
1. Seriously analyze, determine causes
and transform electric precipitator.
1. Design electric precipitator capacity is small. 2. Improve boiler combustion situation,
2. Actual smoke flow exceeds or vibrating is not eliminate wind leakage elements; adjust
proper and secondary raising dust is serious. vibrating period.
Voltage and current
3. Air flow distribution is uneven. 3. Adjust air flow distribution.
are all normal but
4. Cold air intrudes from dust hopper, especially 4. Straighten dust hopper insulation and
16 dust collecting
seriously on outlet electric field. various dust hopper continuous heating.
efficiency is not
5. Combustion is not good and dust is contained 5. Improve boiler combustion conditions.
high.
high level of carbon. 6. Carefully study to determine actual
6. The difference between design coal type and combustion coal type; if the difference
actual coal type is large. with original design coal type is too
large, redefine precipitator parameter to
transform.
1. Polar distances change (polar plate warp, polar
plate is not smooth and undulating, discharge
Produce spark 1. Adjust polar distance and clear soot
electrode line is curved; corrosion and scale
under low voltage formation.
cinder falls off and polar plate and polar glue dust
17 and necessary 2. Improve airflow conditions.
and so on).
corona current 3. Adjust vibration force, adjust vibration
2. Partial blow-by.
cannot be ensured. period and reduce secondary raising dust.
3. Vibration density is too large causing
secondary raising dust.
1. Control dust chemical composition and
1. Smoke level is high and specific resistance and
specific resistance.
When current dust are more.
2. Smoke hardening and tempering.
density is small, 2. HP current voltage peak is too high.
3. Change discharge electrode shape.
18 produce spark and 3. During first operation period, corona voltage is
4. Reduce silicon rectifier transformer
dust collecting too high.
output tap, or with secondary voltage
efficiency reduces. 4. HP power supply silicon controlled conduction
outcome lower silicon rectifier
angle is too small.
transformer.
H voltage and low
1. Control spark rate and adjust maxim
current produce
voltage.
spark and discharge Produce back aroma when specific resistance is
19 2. Smoke hardening and tempering.
and dust collecting pretty high.
3. Change power supply mode (pulse
property
power supply).
deteriorates.
Host computer 1. Relative signals gathering and transmission 1. Inspect host computer acquisition
20
control system have errors. board, interface and relative signal

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measurement 2. Signal source output is wrong. transmission cable, in time fix, adjust and
signals have errors. 3. Transmission from HP and LP tank to host change them.
computer is wrong. 2. Inspect and handle relative signal
4. Host computer handling detection signals data sources (for example: voltage, current,
is wrong. temperature, material level, density,
switches and so on).
3. Inspect and adjust transmission signal
value from HP and LP tank to host
computer.
4. According to real situation, recalculate
and set.
Host computer 1. In accordance with computer
control system 1. Host computer has self fault. illustration inspect, handle or solve it to
21
cannot be normally 2. Computer has computer virus. manufacturers.
started. 2. Clear computer virus.

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5. Pneumatic ash conveying equipment maintenance and overhauling
5.1 Overview
Vinh Tan II-phase unit adopts positive pressure concentrated phase pneumatic ash conveying system to
convey the dust collected by precipitator. In which, one boiler is a unit. Each boiler is equipped with two sets
of double-room four electric field electrostatic precipitators and every boiler electrostatic precipitator is set up
with 32 dust hoppers. Each boiler economizer is set up with 8 dust hoppers. Each boiler air preheater is set up
with 8 dust hoppers. Each precipitator dust hopper is set up with a manual isolating valve, a feed valve, an
expansion joint (only No. 1 and 2 electric fields are set up with ash conveyer)and an ash conveyer (fluidizing
transporter). Two boiler fly ash conveying systems are set up with 3 φ 15m ash silo. Ashes under No.1 boiler
electrostatic precipitator, economizer and air preheater are conveyed to No.3 ash silo and No.2 ash silo
(public ash silo) through positive pressure concentrated phase pneumatic ash conveying system and switching
operation is allowed. Ashes of No.2 boiler electrostatic precipitator, economizer and air preheater are
conveyed to No.1 ash silo and No.2 ash silo (public ash silo) through positive pressure concentrated phase
pneumatic ash conveying system and switching operation is allowed.
The function of ash conveying system is to automatically complete collecting, conveying of ashes under
electrostatic precipitator, boiler economizer and air preheater and pipeline purging, blowing, display the ash
level of ash silo 1, ash silo 2 and ash silo 3, realize the high and low material level alarm of ash silo 1, ash
silo 2 and ash silo 3, realize the remote start-stop control and fault alarm of bag-type precipitators of ash silos
(ash silo 1, ash silo 2 and ash silo 3) so as to complete the function of the whole set of ash conveying system.
The system adopts automatic program control and remote manual operation and local manual operation
can be realized.
5.2 Equipment specifications
5.2.1 Pneumatic ash conveying system performance (one boiler)
Item Unit Value
System output t/h 165
No.1 electric field dust hopper of electrostatic
t/h 122
precipitator
t/h 24(Normal)/122(No.1 electric field quits)
precipitator
t/h 4. 8(Normal)/24(Quit)
precipitator
t/h 1.2
precipitator
Dust hopper of economizer t/h 8
Dust hopper of air preheater t/h 5
3
Average air consumption for system operation Nm /min 43.2(Designed coal BMCR)/65. 5(Designed output)

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Item Unit Value

3
Peak air consumption for system operation Nm /min 120.91(Designed output)
Selected air consumption of air compressor
Nm3/min 120.91(Designed output)
for system operation
Conveying air pressure MPa 0.6-0.7
Controlling air pressure MPa 0.6
238(Designed coal BMCR)/ 360(Designed output)
Average power consumption of system KW
Peak power consumption of system KW 665
5.2.2 Main equipment specifications (Number is one boiler)

System Name Specification Quantity
Pneumatic ash Delivery pump of economizer 6.0E/8 8 sets
conveying system of Manual plug board DN200 8 sets
economizer dust
Feeding dome valve DN200 8 sets
hopper
Pneumatic ash Delivery pump of air preheater 6.0E/8 8 sets
air preheater dust
hopper
Delivery pump of No.1 and
100/8 model 16 sets
No.2 electric field
Manual plug board 200X200 16 sets
Pneumatic ash
Flexible joint DN200 16 sets
conveying system of
No.1 and No.2
Exhaust dome valve DN80 16 sets
electric field
Discharging dome valve DN225 4 sets
Inner- pump level gage Radio frequency admittance 16 pieces
Block-discharging valve DN5O 2 sets
Delivery pump of No.3 and
6.0/8 model 16 sets
Pneumatic ash No.4 electric fields
No.3 and No.4 Feeding dome valve DN200 16 sets
electric field Discharging dome valve DN200 2 sets
Block-discharging valve DN5O 1 sets
Silo-top switching Silo-top switching valve DN225 2 sets
system Silo-top switching valve DN200 1 set
5.3 System layout

Eight delivery pumps of economizer dust hopper shall be combined in series to use one pipeline to enter
A side pipeline of No.1 electric field and form mixed ash with No.1 electric field ash for common conveying;
Eight delivery pumps of air preheater dust hopper shall be combined in series to use one pipeline to

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enter B side pipeline of No.1 electric field and form mixed ash with No.1 electric field ash for common
conveying;
No.1 electric field of electric precipitator is divided into A side and B side, which adopts 4 delivery
pumps respectively to convey electric ash to ash silo through pipeline in series; it can switch to another ash
silo;
No.2 electric field of electric precipitator is divided into A side and B side, which adopts 4 delivery
pumps respectively to convey ash to ash silo by combining with corresponding side of No.1 electric field into
one pipeline; it can be switched to another ash silo; No.1 and No.2 electric fields are set up with 2 pipelines;
No.3 and No.4 electric field of electric precipitator respectively adopts 8 delivery pumps in series to
convey ash to ash silo by using one pipeline; it can be switched to another ash silo; No.3 and No.4 electric
fields are set up with 1 pipeline.
Every boiler delivery is set up with 3 ash pipes.
5.4 Pneumatic ash conveying system maintenance technology and quality standard
5.4.1 Pipe and pipe accessory maintenance
Ash conveying pipe is on violently abrasive state for long time and bears 0.2-0.4Mpa pressure during the
operation. When some part of pipes has wearing and leakage phenomenon, contact operation staff and stop
this unit operation; when medium in the pipe reduces to normal pressure, maintenance staff inspect abrasive
situation of leakage place; if it can be welded up, adopt iron plate supplement welding; if it cannot be welded
because of thin pipe wall, temporarily handle it with putting clamp. Make records of pipe abrasive situation
(including expansion joint and elbow), and make relative changing in schedule maintenance.
Feed dome valve is the most important key part of pneumatic ash conveying system. Spool is made of
wear resistant casted steel material, whose surface conducts hardening treatment; make use of its smooth and
hard surface and make sure good firm contact of rubber seal ring for reliable sealing. Rubber seal ring is
made of specially formulated rubber, which has the features of corrosion resisting, wear resistant, aging
resistance and so on.
Feed valve spool is a spherical dome. During feed valve is on opening and closing process, there is a
1mm clearance between spool and valve body sealing lip, which makes it movement without contact and
whose purpose is not produce friction between spool and valve body. Feed valve pneumatic actuators are full
sealed cylinder structures and directly drives feed valve rotating, which effectively avoids ash entering into
them and producing abrasion and leakage and other problems. When feed valve is in sealing state and after
rubber seal ring inflates, it tightly presses on spherical dome spool forming a very reliably seal band; because
seal ring is soft seal, it can contain particles, which makes it in seal ring and close to spool surface, limits
particles moving and reduces abrasion to some content.
Because seal ring material is rubber, it is easy to be aged and damaged on high temperature and abrasive

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state, please periodically change it after using a certain time. When changing seal ring, loose bolts between
flange and main valve body, take down flange, take out seal ring and aluminum alloy bushing ring, change
new seal ring, reload seal ring and bushing ring into main valve body and tighten again flange, main valve
bolt. In addition, simple maintenance and change seal ring easily.
5.4.2 Change expansion seal ring
1 Switch off gas source and power source and drain residual air pressure of system and parts.
2 After withdrawing dome valve withdraw concave bolts fixing terminal disc and valve body.
3 Record the direction of top disc-seal ring expansion connector relative valve body and withdraw top
disc parts from valve body. Top disc parts include expansion seal ring, inner ring and backing ring and pay
attention to top disc washer number and size, because it will influence spacing of spherical parts and seal
rings.
4 Withdraw expansion seal ring from inner ring.
5 Change abrasive or scratched expansion seal ring;
6 Reinstall in reverse order of withdrawing, use new top disc-valve body washer and make sure new
washer thickness is the same as that of changed one.
5.4.3 Change dome or axle
1 Withdraw dome valve and put it on dry and clean ground;
2 Remove cylinder and make sure spherical parts have been firmly clamped to avoid occurring out of
control movement when withdrawing cylinder;
3 Withdraw fixing spherical parts and drive/pivot axle bolt;
4 Withdraw spherical parts and put them on clean and dry ground;
5 Withdraw axles from valve bodies and inspect whether they are abrasive and damaged;
6 If changing axle, change shaft seal;
7 Make sure axle clean and no burr, and then reinstall in reverse order of withdrawing and make sure
drive axle is matched with valve bottom cylinder support.
5.4.4 Change bearing
1 Withdraw dome valve top disc and axle acceding to the above methods;
2 Withdraw sealing ring fixing ring and shaft seal to inner valve body.
3 With circular seat and bearing fixture smaller than bearing outer diameter, push bearing out of valve
body until into inner valve.
4 From the outside of valve, push changed bearing to inner valve body and at the same time precisely
calibrate oil hole;
5 Reinstall axle and make sure axle clean and no burr until shaft bushing sticks out and withstand
bearing cage;

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6 Reinstall new seal ring fixing ring;

7 Make sure drive axle has been installed on valve bottom cylinder support.
5.4.5 Change non-contact switch
1 Cut off power source and gas source and drain residual pressure of systems and parts.
2 Switch off non-contact switch guide lines;
3 Record spacing of non-contact switch and operation button, loose locking pin and switch off and
withdraw bolts.
4 Switch newly changed non-contact switch into screw hole until the spacing of its bottom and axle
bushing button is the same as the original record spacing;
5 Connect non-contact switch bottom guide lines and switch on power;
6 Switch and adjust non-contact switch and make its upper indicating light keeps the largest spacing
with bottom and operation button;
7 Tighten non-contact switch locating bolt;
8 Switch on power source and gas source and test valve.
5.4.6 Routine inspection after dome valve actions for 1 million
1 Withdraw dome valve top disc, inspect spherical part and seal ring abrasive situation and change them
if necessary;
2 Inspect dome valve axle, seal ring and bearing abrasive situation and change them if necessary;
3 Inspect all cylinders bearings and sealing rings and change them if necessary.
5.4.7 Cylinder Withdrawing and installation
1 Cut off cylinder power source and gas source and withdraw cylinder from valve or support;
2 Withdraw cylinder bolts of two sides and pay attention to avoiding O shape ring when taking out of
bolts.
3 Rotate gears in anticlockwise order until make piston gear breaks away from gear;
4 Withdraw top
5 Withdraw gear wheels from cylinder bottom;
6 Thoroughly clean all cylinder parts;
7 Inspect all parts, make sure whether there are excessive abrasive situations, carefully inspect whether
inner cylinder has scratch and because scratched cylinder has leakage after reinstalling, change it.
8 Use molybdenum disulfide lubricant to lubricate cylinder parts and mop a thin layer oil of on 0 shape
figure, gear and piston;
9 Penetrate cylinder bottom to install gear;
10 Install nylon washer, steel washer and spring on the top of gear;
11 Carefully evenly plug into piston and when rotating piston make them meshing in correct position to

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make sure 90 degree rotating piston gear and small gear meshed in correct tooth. Gear rotates in clockwise
order when piston gathers. Inspect cylinder and make sure cylinder top correctly indicates closure or opening
position:
12 Install in the reverse order of withdrawing cylinder. Pay attention to making sure cylinder and valve
are at opening or closure position at the same time.
5.5 Ordinary maintenance and fault shooting
5.5.1 Feed dome valve
Periodically inspect whether dome valve pressure table indication value is within normal pressure range,
cylinder action is flexible and seal ring is abrasive and loses effectiveness (whether pressure switch has much
soot formation).
5.5.2 Balanced valve
Periodically inspect whether valve action is flexible and valve sealing loses effectiveness.
5.5.3 Pressure reducing valve
Inspect whether pressure reducing valve has gas leakage and water leakage phenomenon and in time
clean spool.
5.5.4 Check valve
Periodically inspect whether spool and seal ring are abrasive and in time change them.
5.5.5 Blowing plug valve
Periodically inspect whether blowing plug valve closure is in place and sealing is normal.

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6. Equipment maintenance and overhaul of ash silo unloading system
6.1 Overview
Vinh Tan II-phase unit is set up with 3 flat base concrete ash silos, which are used to collect the ashes
from two sets of boiler precipitator, economizer and air preheater dust hoppers. Every fly ash silo is set up
with silo-top exhaust air filter with 100% capacity and every ash silo is set up with a set of precipitator on the
top, which can 100% handle the air amount that enters into ash silo to satisfy the delivery air amount of all
the ashes by every boiler that enter one ash silo, ash replacement air amount, air volume entering into ash silo
by ash silo gasified air and the exhaust air volume of ash silo lower dry ash unloader. Silo top is set up with
vacuum pressure relief valve, three ash silos are set up with three sets of vacuum pressure relief valves. Ash
silo is set up with gasified blower and heater and every ash silo is installed with gasified groove at the bottom
to prevent the ash in dust hopper from damping and bonding.
Every ash silo is set up with 3 ash discharging ports, discharging hopper gasification plate to prevent
the ash in dust hopper from damping and bonding. Three ash silos are installed 5 sets of wet-type
discharging system and 4 sets of dry-type discharging system to exhaust ash.
6.2 Main equipment specification

Name Specification Name
Ash silo ontology φ15m; Overall height:27.5m; Height of ash storage section is about 5.5 Ash silo ontology
m
Silo-top precipitator Emission concentration of silo-top bag-type precipitator:≤50 mg/m3 Silo-top
Collection efficiency of silo-top bag-type precipitator:99.99% precipitator
Effective filtration area of silo-top bag-type precipitator:220m2
Boundary dimension:5.7*2.4*2.77
Filter bag specification:φ130*2200mm
Number of filter bag branches:240
Normal use temperature of filter bag :120℃
Maximum use temperature of filter bag:170℃
Blast capacity of ash removal of filter bag (back flushing blast
capacity):1.9-3.8 m3/min
Ash removal frequency:60-120 S
Pulse valve number:24 个
Gross weight:8.2t
Humidified blender Model:TSL-200 Humidified blender
Handling (dry)ash capacity:200 t/h
Screw diameter:940mm
Speed of main shaft:42r/min
Output of water supply:50m3/h
Pressure of water supply:0.2-0.4MPa

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Moisture content of humidified ash:15-25%
Water quality: chemical reverse osmosis concentrated drainage
Model of blender motor:Y250M-6
Blender power:37kW
Voltage:400V
Reducer model:BWD7-23-37
Reduction ratio:23
Gross weight of blender:7. 5t
Dry ash unloader Model:TSZ-200 Dry ash unloader
Handling (dry)ash capacity200t/h
Bulk-head lift travel:1000:3000mm
Bulk-head lift speed:5.86m/min
Elevating motor model:Y802-4
Elevating motor power:0.75kW
Elevating motor voltage:400V
Rotating speed of elevating motor:1440r/min
Reducer model: WP8OA
Reduction ratio:50
Dusting fan model:9-19N0.4
Dusting fan flow:1410m3/h
Air pressure of dusting fan:3500Pa
Motor model of dusting fan:Y100L-2
Motor power of dusting fan:3kW
Motor voltage of dusting fan :400V
Motor rotating speed of dusting fan:2900r/mi n
Level gage model:GF-120
Type of level gage: air-pressure type
Discharging pipe diameter:200mm
Electric feeder Type: impeller rotation type Electric feeder
Model:TG-200
Output (dry ash):200t/h
Maximum output (dry ash):250t/h
Rotating speed:34r/min
Driving method: Chain wheel
Impeller diameter:520mm
Motor model of feeder:Y132S-4
Motor power of feeder:5.5Kw
Motor voltage of feeder:400V
Motor rotating speed of feeder:1440r/min
Type of feeder reducer: cycloidal pin gear speed reducer
Model of feeder reducer:BWD4-34-5.5

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Speed ratio of feeder reducer:34
Manual plug board Structural style: thin-type plug board Manual plug board
Nominal diameter:DN300mm
Nominal pressure:1.0Mpa
Allowable operating temperature:250℃
Seal style: rigidity seal
Pneumatic wear-resisting dome Structural style: bulb seal Pneumatic
valve Driving device: cylinder wear-resisting
Nominal diameter:DN300 dome valve
Structural length:670mm
Seal style: seal ring
Seal air consumption:0.024m3/min
Air supply pressure:0.5--O.7Mpa
Time needed for once cylinder on/off: 10s
Manual flow regulating valve Structural style: Manual plug board Manual flow
Nominal diameter:DN300 regulating valve
Structural length:1100mm
Seal style: Packing case
Sealing material: Graphite packing
Ash silo gasification groove Model of gasification groove:KXC200 Ash silo
Width of gasification groove:B=200mm gasification groove
Length of gasification groove:540m
Operating pressure:0.6MPa
Operating temperature:≤300℃
Venting capability:0.62m3/m2.min
Maximum resistance:0.35kPa
Porosity of gasification plate:37.9%
Ash silo gasification plate Model of ash silo gasification plate:CQHB150 Ash silo
Dimension of ash silo gasification plate:φ150 gasification plate
Operating pressure:0.6MPa
Operating temperature:≤300℃
Venting capability:0.17m3/m2.min
Maximum resistance:0.35kPa
Porosity of gasification plate:37.9%
Ash silo gasification fan Model:SNH811 Ash silo
3
Flow:22Nm /min gasification fan
Pressure rise:98kPa

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Air inlet pipe diameter:DN15Omm
Air outlet pipe diameter:DN15Omm
Air inlet temperature:Air temperature℃
Air outlet temperature:120℃
Weight:930kg
Motor type:Y250M-4
Motor rated power:55kW
Motor grade: four-grade
Motor rated speed:1480r/min
Motor rated voltage:400V
Motor rated frequency :50HZ
Motor phase: three-phase
Motor cooling method: air cooling
Motor installing type: horizontal type
Ash silo gasification fan Model:SNH809 Ash silo
3
Flow:14Nm /min gasification fan
Pressure rise:68kPa
Air inlet pipe diameter:DN15Omm
Air outlet pipe diameter:DN15Omm
Air inlet temperature: Air temperature℃
Weight:850kg
Motor type:Y200L-4
Motor rated power:30kW
Motor grade: four-grade
Motor rated speed:1470r/min
Motor rated voltage:400V
Motor rated frequency :50HZ
Motor phase: three-phase
Motor cooling method: air cooling
Motor installing type: horizontal type
Ash silo gasification air heater Model:DYK75 Ash silo
3
Rated flow:22Nm /min gasification air
Air inlet temperature:45℃ heater
Power:75kW
Input voltage:400V
Shell bearing pressure:0.8MPa
Equipment weight:230kg

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Ash silo gasification air heater Model:DYK55 Ash silo
3
Rated flow:14Nm /min gasification air
Air inlet temperature:45℃ heater
Power:55kW
Input voltage:400V
Shell bearing pressure:0.8MPa
Equipment weight:220kg
6.3 Overhaul technology and quality standard of ash silo unloading system
6.3.1 Maintenance technology and quality standard for wet blender
Overhaul item Overhaul technology Quality standard
Preparations Principals of overhaul shall deal with working
Qualified filling.
before overhaul sheet
Measurement 1. Measure the axial and radial clearance.
Remove the screws on protective cover
before overhaul 2. Record the shim number and thickness.
Remove gland Remove the shaft sealing cover screw, remove the Replace the damaged land screw.
retainer plate packing, and loose the gland with a copper bar.
Remove the screw Remove the screws on bearing cover.
Measure the thickness of pad.
bearing body Check for the abrasion conditions.
Remove the Lift the main shat to check the abrasion
connection screw conditions of the impeller Replace the impeller if its abrasion is greater than 2/3
of short shaft and Remove the flange screws of short shaft and main Check the abrasion conditions of the impeller.
main shaft shaft to check the abrasion conditions
Lift out main
Lift out the gear part of main shaft and bearing
shaft and bearing Measure and record.
body
body
1. Remove the auxiliary gear set with wheel
There is no defect, like pitting, peeling, crack and
puller.
corrosion on the internal and external balls of the
Remove the gear, 2. Remove the retaining screw of bearing
bearing.
bearing body and body to remove it.
The maximum radial clearance between bearing outer
bearing 3. Loosen the lock net of rigid bearing.
ring and its body is 0.04mm, otherwise, replace the
4. Clean up the parts and check the abrasion
bearing body.
condition.

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1 The clearance of bearing and its end cover:
0-0.04mm.
2 The maximum clearance of bearing outer ring
Install bearing and fix its lock net. After clean up and bearing body is 0.038 mm and the maximum
Assembly bearing bearing, add a proper amount of lubricating interference is -0.012 mm.
and bearing body grease. Assemble the bearing body and evenly 3 Original bearing radial clearance is: 0.02-0.03
fasten the screws on the end cover of bearing. mm and the maximum of old bearing is not greater
than 0.30 mm.
4 The interference connected by the bearing
endothecia and shaft is 0.003-0.046 mm.
Reassemble the
Lift to set the gear part of main shaft and shaft Measure that the maximum radial and axial deviation
main shaft and
body of driving gear and driven gear
bearing body
Install the packing frame uprightly and without
Fill both sides Elastic and is with refastening degree to avoid ash
deflection. Screw down the packing pressing
with packing flying.
bolts evenly. Stagger the packing by 90°-180°.
6. Measure that the maximum radial and axial
deviation for the center of driving gear and driven gear
Alignment connects the flange bolts and is not greater than 0.10mm.
Alignment and
assembles its protective cover, trail operation and 7. The occlusion contact side is greater than 75%.
trial operation
recall the working sheet. 8. There are at most 3 pieces of anchor shims.
9. Fasten the connecting screw after the adding
with spring cushion
6.3.2 Maintenance technology standard for bulk machine

Principals of overhaul shall deal with working
Before overhaul Qualified filling.
sheet
1. Remove the thermal material level detection
hose The steel hoisting tract shall be free of burr and the
2. Loosen the steel wire rope lock parts, and edge id smooth, otherwise, do repairing and polishing
remove the three hoisting rope from hoist wheel Loosen the bolt in a cross manner, and with a holder
3. Loosen the bolts at the ash intake valve and supporting the rheid of bulk machine at the same time
Disassembly of
flange connected with bulk machine
bulk machine
4. Place the unloaded bulk machine to a flat
overhaul place with lifting tool car
5. Screw out the hexagon screws of semi-steel rope
Check that the steel rope is free of broken strand, rust
locking part and get through the guiding element
and burr, otherwise replace it
steel rope sleeve to remove the steel rope

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6.Loosen hexagon screws of connection ring on
cementing valve and remove the connection ring
and bag
There is no crack and fracture on connection ring and
7. Check the connection ring and bag
light abrasion on the bag, otherwise replace it
8．Loosen the lock screw of connection ring
successively, remove the connection ring and
Place them successively and make marks
bellow, and remove the wearing partition cone in
turn
The through-flow surface abrasion of the wearing
partition cone is not greater than the half of the
9. Check the wearing partition cone
thickness of metal wall and is free of roll rim and ,
damage phenomenon, otherwise, replace it
10. Remove the bolts and ash discharge Check the wear condition of ash soot door
material level measuring point turns over thermal
11. Take off the measuring point confinement
processing
12. Check for the reduction gear of lifting motor Clean and replace the new oil
1. Assemble the soot door and material level
measuring point confinement
2. Bellow and wearing partition
3. Align cones by marks. Install and lock the
locking screw and linking ring lock, to make the
Reassembly of
bellow and wearing partition to be a whole
bulk machine
4．Align and upright bulk machine with lifting tool
car, to make the center line of the whole ash intake
Prevent the distortion and folding of the bag
pipe and bellow keep vertical to the upright
installed flange
5. Install hoisting rope on hoist wheel Brush lubricating grease on steel rope for protection
6.3.3 Maintenance technology standard for electric feeder

Principals of overhaul shall deal with working
Before overhaul Qualified filling.
sheet
1. Close the lower damper of big hooper The damper shall be closed tightly and free of block
The abrasion of chain and sprocket is less than 1/3
2. Remove chain and sprocket
and free of crack and breakage
Disassembly of
3. Disassemble reducer base, displacement and Support the rotor bearing, make it be on the same axis
feeder
disassembled overhauling with its noumenon to avoid damage
4. Take out rotor and check the clearance and The impeller abrasion is qualified and the rotor is free
abrasion condition of impeller and casing if abrasion and groove

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Check the bearing abrasion condition and there shall
5. Cleaning and overhauling of parts
be free of pitting
1. Assembly of shaft sleeve and bearing lubricating
Bearing clearance is 0.15-0.2mm
grease
2. Lift the rotor in position, assemble the end After filling with packing, compact the sealing gland
cover, fill with gasket and fastening to prevent leakage
Reassembly of
3. the reducer is in position and align with ash Which requires the two sprocket shall be on a same
feeder
unloader (feeder) as datum plane and the chain shall be parallel
Feeder shall be free of blockage, leakage and
4. Take trial operation as the operating standard abnormal noise and the bearing temperature rise shall
be less than 35℃
6.3.4 Maintenance technology standard for bag precipitator

Before overhaul Principals of overhaul shall deal with working sheet Qualified filling.
Check the fan duct Clean up the dust and dirt with fan and duct
Replace the impeller with serious abrasion. For the
Check the fan impeller impeller imbalance caused by uneven abrasion or
Dusting fan other factors, find the dynamic balance
overhaul Replace the bearing lubricating oil/grease, replace
Check the abrasion condition
bearing if abrasion is serious
The sealing of each part is good and the tighten
Check sealing
fastener is reliable
Check whether there is leakage and the sealing gasket
Precipitator box age the valve shall keep tight. Replace it if it is aged or
damaged
Check whether there is damage or deformation.
Precipitator Check the spray torch Replace if there is and replace the flange sealing
overhaul gasket
After the removal of spray torch, check the filter-bad
Replace filter-bag
one by one, replace if it is with damage
Clean up the filter, replace the solenoid valve which
Solenoid valve
does not work and with leakage
The operation is free of noise and fan vibration is
qualified and free of friction. The precipitator and
Trial operation Take trail operation as the operating standard
compressed air line are free of leakage and ventilate
normally

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6.3.5 Maintenance technology standard for gasified fan

6.3.5.1 Overhaul content
6.3.5.1.1 Minor overhaul
1 Clean the grey scale on rotor surface and check the clearance of each part;
2 Check the bearing and gear drive part;
3 Check the bearing box, gear case oil level, add or replace lubricating oil;
4 Fasten bolts;
5 Adjust the degree of tightness of the belt.
6.3.5.1.2 Medium overhaul
1 Including the content of minor overhaul;
2 Clean tolling bearing and bearing box and replace bearing;
3 Clean and check the driving gear and qualified parts;
4 Clean sealing device and replace the packing or sealing ring;
5 Measure and adjust the clearance of each part;
6 Check and replace coupling and accessories;
7 Clean up gas filter;
8 Repair and clean up the lubrication system;
9 Check the safety valve, automatic control device and pressure regulator.
6.3.5.1.3 Major overhaul
1 Including the contents of medium overhaul;
2 Repair or replace the main shaft, enclosure, front or back wall board;
3 Repair or replace the driving and driven rotors, and look for their static balance;
4 Calibrate the levelness of base.
6.3.5.2 Overhauling method and quality standard
6.3.5.2.1 Items needing attention during overhaul
1 Before remove the blower, do measure the inner clearance;
2 Remove the gasket on joint surface carefully, and measure the thickness and print marks on key parts.
6.3.5.2.2 Machine body
1 The machine body shall be free of damage and crack;
2 The body installation unlevelness is not greater than 0.04mm/m.
6.3.5.2.3 Rotor
1 Never remove the rotor and shaft if not requires for replacement;
2 There shall be free of defects, like sand hole, air hole, crack, on the surface of rotor;
3 The unlevelness of both ends of rotor is not greater than 0.02mm. And the non-parallelism of both

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ends of rotor and wallboard is not greater than 0.05mm;

4 The diameter runout value of the rotor end is not greater than 0.05mm;
5 Correct the rotor dynamic balance and static balance at first.
6.3.5.2.4 Shaft
1 The shaft surface shall be smooth and free of phenomenon like grinding crack and crack;
2 The ovality and telescopicity of journal shall not greater than the half of the tolerance of shaft
diameter;
3 The journal non-straightness shall be not greater than 0.02mm/m, in general, the non-straightness of
the whole shaft is not greater than 0.04mm/m;
4 The non-perpendicularity of shaft and rotor end shall be with 11mm and not greater than 0.05mm.
6.3.5.2.5 Coupling
1 There shall be no crack and damage on the surface;
2 The key shall contact with the keyway side tightly, and there shall be a clearance of 0.1～0.4mm
between the upper plane. Broaden the old keyway but not greater than 10％ of the keyway width.
6.4 Daily maintenance and troubleshooting
6.4.1 Fault cause and exclusion method of electric pulse precipitator
No. Trouble Cause Exclusion method
Change or mend filter-bag; Use the same material as
Ash coming out from exhaust Filter-bag falls off
1 filter-bag; do not only use line to sew; usage period of 1 to 2
port or is damaged
years
Find ash coming out from clean ash
2 Adjust clean-ash period
exhaust port after cleaning excessive
6.4.2 Fault cause and exclusion method of wet stirrer

Wear and deformation of the main bearing
Repair or replace
Bearing damage
1 Higher noise Replace
Loose anchor screw of bearing bracket or
Tighten anchor screw
reducer
Wear and deformation of the main bearing
Repair or replace
Oil temperature of Bearing damage
2 Replace
reducer is too high Too much ash in the reducer box increases
Flush timely
resistance
Low water pressure Increase water pressure
Insufficiency water
3 water shortage Use hand to adjust the valve opening
content
blocking nozzle Clean and replace

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Leaking ash of bearing Wear of the main bearing Repair or replace

4
end Wear of gland packing Replace
6.4.3 Fault and exclusion method of bulk machine

No. failure Cause Exclusion method
1.Wiring troubles 1.Exclude wiring troubles
2. Brake block does not 2.Take out rear cover of motor, loosen
1 Hoist motor fails to act disconnect screw of brake block,then tighten bolt of
3.Loose anchor screw of bearing brake block after operating in positive and
bracket or reducer inverse for several times with power.
The reducer cannot stop running 1.Wiring troubles
1. Exclude wiring troubles
2 timely after the up and down 2.The switching place of counter
2.Replace the switching place of counter
position of bulk-head are in place is damaged
1.Wiring trouble 1. Exclude wiring troubles and inner
Fail to load after bulk-head is in
3 2.Loosing rope switch unit is trouble of switch 2.Adjust pulley and the
place
incorrect position of spring
Bulk-head fail to lift or descend, Steel cable winds shaft or blocks
4 1.Readjust the position of steel cable
and motor works normally in the pulley
No alarm when full of materials or 1.Level gage breaks 1.Replace level gage
5
alarm when materials are not full 2.Level gage is not in place 2.Adjust level gage in place
1.Sweep-up pipe is damaged or
blocked 1. Clean dust of sweep-up pipe or replace
Ashes coming out from the joint 2.Air volume of dust exhaust it.
6 part of bulk-head and the port of blower is not enough or blower 2.Increase the air volume of blower or
tank fails exclude blower troubles
3.Seal surface of bulk -head is 3.Replace seal surface of bulk-head
damaged
6.4.4 Fault and exclusion method of gasified blower

1. Clearances between impeller and the body 1.Replace wearing parts
of blower caused by wear increase 2.Adjust the clearance according to
1 Air volume is not enough
2. Fit clearance changes. the requirement
3.System leaks 3.Check and eliminate the leakage
1. The inlet of filter blocking causes an
increased resistance to form negative pressure 1.Clean filer screen
(Under the condition of constant outlet 2.exclude after inspection
2 Motor overload pressure, boost pressure increases). 3.Adjust the clearance
2.Pressure of outlet system increases 4.Replace gear
3. Friction between stationary part and 5.Replace bearing
moving parts
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4.Gear is damaged
5.Bearing is damaged
1. Oil quality is poor and oil temperature is
1.Replace lubricating oil
too high.
2.Inspect air intake
2. Gas temperature of inlet increases.
3.Adjust the clearance
3. Friction between stationary part and
3 over temperature 4.Adjust or replace gear after
moving parts
inspection
4. The gear mesh is abnormal or damaged.
5.Replace bearing
5.Bearing is damaged
6.Adjust quantity of oil
6. Excessive or insufficient lubricating oil
1. Fasteners between gear ring and gear hub
loosen and occur displacement beyond
limitation. 1.Locate and fix after adjust clearance
2. The wearing surface of gear increases gear 2. Adjust the clearance
clearance, which changes clearances between 3.Inspect axis and replace impeller
impellers. key
Collision among the
4 3.Gear and impeller key loose 4.Adjust and replace axis
impellers
4. Master-slave moving axis bends beyond 5.Eliminate impurities or scaling
limitation. 6.Replace bearing
5. The body of blower is mixed with 7.Inspect reasons of overpressure and
impurities or scaling forms due to medium. then exclude
6.Bearing wear and increased clearance
7.Over-rated pressure operates
1. Bearing wear and increased clearance 1.Replace axis
Friction between impeller
2. Master-slave moving axis bends beyond 2. Adjust and replace
5 and radial direction of
limitation. 3.Inspect reasons of overpressure and
blower casing
3.Over-rated pressure operates then exclude
1.Clearances of C,D is beyond permissible
value 1.Adjust the clearance
Friction between impeller
6 2.The end surfaces of impeller and wallboard 2.Eliminate impurities or scaling
and wallboard
attach and stick impurities or scaling 3.Replace bearing
3. Bearing wear and increased clearance
1.Find a balance
1.Unbalance rotor
2.Adjust safety valve
2. Safety valve is blown open.
3.Replace bearing
3. Bearing wears or is damaged.
Abnormal sound or 4.Replace gear
7 4. Gear is damaged.
vibration overrun 5.Fasten after inspection
5.Foundation bolt or other fasteners loose
6.Fill oil or replace oil
6. Gear oil is shortage or degradation
7. Strengthen or increase the pipe
7. Pipeline resonance
support

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1. Valve does not open or open too small. 1.Open valve fully
2. Outlet resistance increases. 2.Adjust outlet of device
8 Exhaust pressure rise
3.Too fast turning and too much air 3.Reduce turning speed and exhaust
4. diffuser tube blocking 4.Eliminate sundries

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7. Operation specification of slag discharging system
7.1 Overview
Vinh Tan Phase II slag discharging system adopts water-cooling type submerged scraper conveyor
scheme. For boiler B-MCR working condition by using designed coal quality, the slag discharging quantity is
21.11t/h. Boiler deslagging device is arranged as follows: water seal groove is under water seal plug board
and slag receiving well is under water seal grove, hydraulic shut-off valve is under slag well, submerged
scraper conveyor is under hydraulic shut-off valve and submerged scraper conveyor is arranged on the
ground. For normal operation, hydraulic shut-off valve’s door panel is inserted in the water channel of
submerged chain conveyor to keep the seal of boiler. Water seal groove, transition slag well, shut-off valve,
submerged scraper conveyor and relevant ancillary facilities shall satisfy the seal requirement for boiler’s
operation. Make-up water of submerged chain conveyor is supplied by water supply pump under buffer tank.
Every boiler shall be set up with 2 water supply pumps, one for delivery and one for standby. Water seal
groove, transition slag well, hydraulic shut-off valve, submerged scraper conveyor and ancillary facilities
shall be arranged at the bottom of hearth; elongated submerged scraper conveyor shall operate continuously;
head of submerged scraper conveyor, electric three-links, slag silo (two for each boiler) shall be arranged
outside boiler room. Every boiler slag silo is set up with 2 sewage discharging pumps, one for delivery and
one for standby. Submerged chain conveyor overflow water flows to the boiler room overflow water pool and
delivered to high-efficiency concentrator and buffer tank through overflow water pump. Every unit is set up
with high-efficiency concentrator and buffer tank. Two high-efficiency concentrators and buffer tanks are
installed in ash silo area together. Every concentrator and buffer tank is set up with 2 sets of stuff discharging
pump at the bottom, one for delivery and one for standby.
7.2 Main equipment specification
7.2.1 Equipment performance
Item Unit Value
Normal output of submerged chain conveyor t/h 21
Maximum output of submerged chain
t/h 84
conveyor
Scraper speed (normal speed) m/min 1
Scraper speed (maximum speed) m/min 3
Chain speed m/min 1-3
Noise at 1m away from equipment when
dB(A) 85
equipment is operating
Suspended solid content of concentrator
ppm
overflow
Suspended solid content of buffer tank
ppm ＜100
overflow

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Item Unit Value

3
Concentrator output m /h 500
3
Buffer tank output m /h 500
7.2.2 Main equipment specification(one stove)

Name Specification Quantity
Slag well Type: Self-supporting 1 set
3
Effective volume:210m
Seal water volume:14t/h
Seal water pressure:0.2-0.3MPa
Cooling water volume:95t/h
Cooling water pressure:0.2-0.3Mpa
Slag storage volume:180m3
Slag storage time:≥6 hours
Output quantity:4
Hydraulic shut-off valve Type: fan-type 4 sets
Door leaf quantity of hydraulic shut-off door: side door2×4 doors; end
door 2×1
Thrust of hydraulic cylinder:50KN
Stroke of hydraulic cylinder:260mm
Door size: 1100×800mm
Hydraulic shut-off door oil Form: electro-hydraulic control cabinet 1 set
Hydraulic pump model: CB-FA10C
Outlet oil pressure:12Mpa
Motor model: Y112M
Voltage:400V
Power:4KW
Water-immersion type Type: water-immersion type scraper, elongated oblique ascension 1 set
submerged scraper Model:CBH20
conveyor Normal output:21.1t/h
Maximum output:85t/h
Normal speed of chain:≤1m/min
Maximum speed of chain:≤3m/min
Water quality of cooling water: industrial circulating water
Water temperature of cooling water:38℃
Cooling water pressure:0.2Mpa
Normal usage of cooling water:68m3/h
Maximum usage of cooling water:120m3/h
Wash water volume of chain:4m3/h
Wash water pressure of chain:3Mpa
Normal temperature of overflow water:≤55℃
Maximum temperature of overflow water:≤60℃
Ash content of overflow water: 1000ppm

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Outer width of groove body:2000/2600mm
Horizontal section engine body length:39m
Inclined section engine body length:36m
Upper groove water depth of engine body:≥2m
Upper groove water volume of engine body:≥200 m3
Hydraulic drive device Hydraulic tank volume:300L 1 set
Hydraulic pump model:PV080
Hydraulic pump flow:117.6 L/min
Hydraulic pump pressure:35Mpa
Hydraulic pump shaft power:27Kw
Hydraulic pump torque:2×132KNm
Motor model: QA225M4A
Motor power:55Kw
Voltage:400V
Motor speed:1470r/min
Power factor:0.88
Efficiency:93%
Electric three-links Model:DST-800 1 set
Motor model:Y90S
Motor power:1.1Kw
Boundary dimension:800×800mm
Slag silo Model:TSC-8 2 sets
3
Effective volume:165 m
Diameter:Φ8m
Bleeding component specification:1000X270mm
Overall length of bleeding component:4m/silo
Model of slag discharging door:TF914
Caliber of slag discharging door:Φ900mm
Vibrator number:3 sets/ silo
Vibrator power:0.25Kw
Slag storage time:8h
Model of material level Slag silo control cabinet size:2.0×1.5×2.2m
Concentrator Model:TNSD-12 1 set
Diameter of silo body:Φ12m
Sewage:500 m3/h
Effective volume:420m3
Effective sedimentation area:800m2
Inlet suspended solids content:<2000ppm
Overflow water suspended solids content:≤300ppm
Diameter of harrow body :1.4m
Diameter of rotating harrow: 11m

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Rotating harrow speed:0.14r/min
Harrow lift height:0.4m
Allowable maximum granularity for thick liquid inlet:30×30mm
Drive motor model:Y100L2-4
Main harrow motor power:3Kw
Voltage:400V
Reducer model:BWD3-42-187
Reduction ratio:187
Harrow lift motor power:2.2Kw
Flushing water volume:8 m3/h
Flushing water pressure:0.6Mpa
Thick liquid outlet valve diameter:DN200mm
Buffer tank Model:THH-12 1set
Tank body diameter:12m
Effective volume:400m3
Sewage treatment capacity:500m3/h
Inlet suspended solids content:≤350ppm
Quality of sewage:<100 mg/l
Circulation nozzle number:4
Circulation nozzle diameter:8mm
Flushing nozzle number:3
Flushing nozzle diameter:8mm
Total water consumption of nozzle:45m3/h
Water supply pressure for nozzle:0.6MPa
Overflow pump Model: 150/100E-AHK 2 set
3
Rated flow: 270m /h
Range of lift: 0.38MPa
NPSH: 6m
Pump rotate speed: 1480r/min
Pump efficiency: 53%
Pump shaft power: 48KW
Sealing form: packing+auxiliary impeller sealing
Drive mode: (direction connection) pin coupling
Motor type: horizontal type
Motor model: Y2-250M-4
Motor rated power: 55KW
Maximum operating shaft power of motor: 48KW
Motor rated frequency: 50HZ
Motor rated speed: 1480r/min
Motor rated voltage: 400V
Motor rated current: 103.2A

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Water supply pump Model: 100ZS-50B 2set
3
Rated flow: 280m /h
NPSH: 6m
Pump shaft power: 87.1KW
Drive mode: direction connection
Motor model: Y2-315S-4
Motor rated current: 201A
Sewage discharging pump Model: 40PV-SP Two sets
3
(slag silo) Rated flow: 20m /h
Pump efficiency: 38.8%
Drive mode: belt drive
Motor model: Y2-160M1-2
Maximum operating shaft power of motor: 6.41KW
Motor rated current: 21.3A
Sludge pump Model: 75/50D-HHK Four sets
3
Rated flow: 30m /h
NPSH: 6m
Drive mode: belt drive

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Motor model: Y2-225M-4
Motor rated current: 85A
7.3 Overhaul technology and quality standard of deslagging system

7.3.1 Thickener overhaul
7.3.1.1 Minor overhaul content
1 Check the gear meshing and wear condition.
2 Check each bearing and adjust the clearance.
3 Check the abrasion of each bolt and pin roll.
4 Check the abrasion of roller track and rack.
5 Check the usage of rake rack and tine.
6 Check the controller, resistor or replace collector device.
7 Fasten each bolt.
7.3.1.2 Major overhaul content
1 Including all items of minor overhaul.
2 Clean and measure related parts.
3 Overhaul all parts and components.
4 Replace and repair roller, shaft sleeve, large and small gear, all worn parts and components.
7.3.1.3 Overhaul quality standard
1 Track part
Set track along with the pool which requires that the diameter error of track central circle shall not
exceed ±5mm, the upper surface of connector of both tracks shall be on a same plane and its error shall not
exceed 0.5mm, while the maximum unlevelness of the track plane corresponding to any position shall not
exceed 1.5mm.
2 Rake rack and tine
The dimension error of rake rack shall meet the following requirements: length error < 8mm height
error < 4mm plane warping error < 8mm in a total length and < 3mm in width.
3 Central pressure bearing
The ball track width of up and down compression rings for central pressure bearing shall be no more
than 3/4 of the bearing bead diameter, ball wear is not greater than 2mm in diameter, when the up and down
pressure rings and ball appears obvious abrasion, replace them at the same time.
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7.3.1.4 Dead load trial operation

The dead load test shall not less than 2 hours and meet with the following requirements:
1 The current shall be stable without abnormal fluctuations.
2 The temperature rise of driving mechanism bearing shall not exceed 35℃ for the surrounding medium
temperature, and the highest temperature shall not exceed 60℃.
3 The rake rack speed shall conform to the parameter specification.
4 All the parts of the machine shall be free of interference phenomenon, abnormal sound and beat
phenomenon.
5 When the rake rack turns around one time, rake tine shall sweep all area of the pool bottom and keep
the clearance regulated by the pattern with the pool bottom.
7.3.1.5 On-load trial operation
After dead load test adjustment is normal, take on-load test which shall not less than 24 hours. At this
point, check the thickener for its processing ability, slurry intaking concentration, slurry discharging
concentration and the quality of overflow water, to determine whether the device operates normally.
7.3.2 Submerged scraper conveyor overhaul
7.3.2.1 Disassembly of submerged conveyor.
1 Clean and check the machine body, main rotation, expanding device, backward wheel, riding wheel,
chain and scraper.
2 Measure the rotation gear, sprocket, the connection of bearing and bearing and the connection of
bearing and shaft.
3 Replace the damaged components.
4 Assemble the submerged conveyor.
5 Measure and adjust the chain.
7.3.2.2 Submerged conveyor overhaul
1 Submerged conveyor body inspection
Requirements: there shall be free of bending or distortion on stand column, beam and their side plate and
bottom plate. There shall be no defects like crack, sand hole, pit and corrosion at the welded junction of the
machine body surface.
 The maximum allowable bending error of stand column and beam shall exceed 10mm
 The distortion of stand column and beam: when their length is less than 5m, the distortion value
shall not exceed 3mm; when their length is greater than 5m, the distortion value shall not exceed 7mm.
 For the steel frame assembly adopting bolted connection but not welding, it requires that the bolt
shall be fasten and reliable, not using unfinished bolt. Each bolt and hole shall be even and don't allow the
individual bolt stress phenomenon caused by wrong eye. If found wrong eye, it shall take processing method

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of plugged hole drill or reamer broaching, but the expanding rate shall not exceed the 5% of the track
diameter. After fastening. Bolt shall show 2~3 button of the nut.
2 Main driving wheel assembly overhaul
1) Gear inspection
 The large and small driving gear shall be complete and the tooth shall be smooth without burr.
Replace the tooth if the abrasion reaches the 1/4 of the original thickness. The tooth contact side shall be over
90％. The jointing force of gear and shaft shall be 0.03 mm～0.04mm. The clearance between the tooth top
and bottom shall be 0.40mm. The tooth meshing clearance is 0.15 mm～0.30mm. During disassembly, use
special tool to jacking of pinching-out on the special frame, to avoid damage the shaft and its journal.
 The jointing force of wheel roll and shaft is 0.03 mm～0.04mm, and the locating pin hole on hub
shall be free of deviation (decentration) which may make the locating pin cannot plug in or out. The
allowable skewed error of the keyway axis and shaft hole axis on hub is 0.03mm.
 The connection of big gear ring and hub adopts clearance connection and the connecting clearance
is 0.5mm.
 The connection jointing side of big gear ring and hub shall be clean and polished; the connecting
clearance is 0.5mm.
 For the large and small gear rings, the axial moving is ≤1mm, and radial moving is≤0.5mm.
 For the large and small gear rings, there shall be no phenomenon, such as broken tooth, tooth
surface fatigue pitting, tooth surface wear and the plastic deformation of gear tooth.
 When to plug the lug boss of baffle fully into large gear ring, the jointing side of lug boss with large
gear ring, and lug boss with hub shall ensure that it could contact evenly when turns to any angle relatively.
2) Bearing body overhaul
 The bearing cover on bearing base and the glove of the bearing seat shall be cleaned up and the
through shall be free of mechanical damage, burr and the trench. There shall be no crack on bearing cover
and base, and the groove connects with lug boss.
 The radial connecting of the outer bearing ring and cover is a radial clearance of 0.1mm～0.15mm.
 The clearance between bearing and bearing housing end cover is 0.0mm～0.05mm.
 Bearing housing oil path should be smooth, and the injected calcium base fat quantity should better
be 10～15 cups.
 The felt ring in transparent cover shall not be broken and damaged. The felt ring head joint shall be
cut into inclined joint lapped by 30～45 degree. There shall be no oil immersion phenomenon on felt ring.
After each major overhaul, in principal, the felt ring shall be replaced. The felt ring dimension shall conform
to the requirements and the connection clearance of the inner felt ring circle and shaft diameter shall be
0.10mm.

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3) Overhaul of shaft
 Curvature of shaft shall not be more than 0.10mm. There shall be no crack and groove mark, and
shaft shoulder, journal and key slot shall be smooth and clean, and no burr. The ovality and conicity of
journal shall be less than 0.06mm and degree of finish shall be ▽5.
 Tightening force of bearing and shaft shall be 0.02mm～0.04mm.
 There shall not be ring rib layer deeper than 0.5mm and crack on the surface of shaft sleeve, and
tightening force of shaft sleeve shall be 0.03mm～0.05mm, with no defect of wear and partial grinding at
both ends of shaft sleeve.
 Cylindricity of roller shall be 0.2mm, with no longitudinal or lateral layer after wear deep as
0.5mm～1mm on the surface, and there shall not be defects such as porous sand hole and crack around crater
on both sides of roller, otherwise repair welding and polishing shall be needed.
4) Overhaul of chain wheel
 Suitable tightening force of hub and shaft shall be 0.03mm～0.04mm, the permissible deviation of
deflection between axis of key slot and shaft hole on the hub shall be 0.03mm.
 Chain wheel and hub cooperate through clearance, with the fit clearance of 0.5mm.
 Fitting interface between chain wheel and hub and screw hole on big gear ring shall be cleaned up
and grazed; with the fit clearance of 0.5mm.
 Axial moving between chain wheel and hub shall not be more than 1mm, while radial moving shall
not be more than 0.5mm.
 Gear teeth symmetry shall be synchronized when assembling two pairs of chain wheels. Both sides
of clearance between vertical slot and standing chain ring shall be 3 mm～5mm respectively, while length of
flute between two contiguous vertical slots shall be about 10 mm～20mm longer than horizontal chain ring.
3 Overhaul of flight chain assembly
1) Overhaul of flight
 There shall be no crack at the joint between the flight and connector assembly on both ends of it.
Both sides of connector assembly shall be parallel and thickness uniform and no bend. Connector assembly
shall be over four fifths thickness of original. The bolt with 2～3 buttons exposed after being locked shall be
sealed or soldered by opening pin.
 Non-parallelism of side on both sides of flight shall not be more than 0.4mm; Wear of side to
shovel slag shall not be more than 15mm; Centre distance of axis pin on both sides shall not be over 0.5mm.
 Two contiguous flights shall parallel to each other, each one shall be vertical to chains on both sides,
angle between bevel and horizontal plane shall not be bigger than 15 degree, and opening direction of slot
scraping shall coincide to moving direction.
2) Overhaul of chain

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 Size deviation of unilateral chain’s overall length shall not be over 8mm; deviation per meter of
corresponding chain shall not be over 1mm. When replacing chains, both sides shall be replaced in the
meantime and corresponding chains shall be the same in length.
 Wear of chain ring and connector shall not be over 1/3 of ring diameter. There shall not be crack
around weld area of chain ring.
 Straight pin in connector shall be unbroken, with no straight pin lost. Serration shall be unbroken,
with no damage and rust phenomenon.
 Deviation of two chains’ centre distance shall not be bigger than 0.5mm. Keep good mesh between
chain and chain wheel, with tension side of both sides of chain aboard and loose side infra.
4 Overhaul of guide pulley up and down
There are two top pulleys in extrorsely structure; there are bottom pulleys, bottom pulley of head are
installed symmetrically at both sides, bottom pulley of tail is concave tooth structure, supported by thru-shaft.
1) Overhaul of guide pulley up and down
 There shall be smooth and no burr in vertical slot of guide pulley, and clearance of both sides
between vertical slot and vertical chain ring shall be 3mm～5mm respectively.
 Felt ring in transparent cover shall not be broken and damaged, joint of felt ring attachment shall be
cut to inclined joint of 30～45 degree, and no extraction phenomenon on felt ring. Felt ring shall be replaced
in principle after every heavy repair. Size of felt ring shall meet the requirement, and fitting clearance
between circle and shaft diameter in felt ring shall be 0.1mm.
 Boss for transparent cover and blank cap on both sides of guide pulleys shall insert into guide
pulley entirely and be uniformly combined with outer ring of bear, outer side of transparent cover and blank
cap and interface between chain wheel and hub shall guarantee uniform contact. Oil-way of guide pulley
shall be smooth.
 There shall not be crack and gas hole during grand of guide pulley and body welding.
 Structure of carrier roller is basically the same with guide pulley, so overhaul is the same as above.
Carrier rollers on the body distribute every one meter generally.
5 Overhaul of tension roller’s assembly
1) Overhaul of chain pulley
 Gear teeth symmetry shall be synchronized when assembling two pairs of chain wheels, and it shall
be smooth and no burr in vertical slot, and both sides of clearance between vertical slot and standing chain
ring shall be 3 mm～5mm respectively, while length of flute between two contiguous vertical slots shall be

Page 58 of 71
about 10 mm～20mm longer than horizontal chain ring.

 Boss of transparent cover on both sides of chain wheel shall insert into chain wheel entirely and be
uniformly combined with outer ring of bear, outer side of transparent cover and interface between chain
wheel and hub shall guarantee uniform contact.
 Assembly interface between transparent cover’s outer side and hub and screw hole on chain wheel
shall be cleaned up and grazed. There shall not be groove mark which shall make mantle stationary of bear
loose on surface of the circle in chain wheel causing by friction.
 Retaining ring shall cling to inner ring of bear, and height of snap ring is 1/2 to 2/3 the thickness of
bear’s inner ring generally.
2) Overhaul of worm shaft
 Curvature of worm shaft shall not be more than 0.04mm, and surface of worm shaft shall be
smooth, with finish degree of ▽5.
 Worm shaft shall be with a certain extent of strength, with no abrasive wear and break off on its
screw tooth, and central distance between worm shaft and trapezoidal screw shall be 110 mm 土 0.044mm.
 Suitable tightening force of bear and worm shaft shall be 0.0mm～0.01mm, and boss for
transparent cover shall insert into stand of worm shaft entirely and be uniformly combined with outer ring of
bear. Outer side of transparent cover and interface between sides of stands shall guarantee uniform contact.
3) Overhaul of worm wheel
 There shall not be phenomena of gear teeth breakage, fatigue pitting of tooth surface, tooth surface
wear and gear teeth plastic deformation on gear teeth of worm wheel.
 Gear teeth of worm wheel shall be intact, smooth and no burr, and it shall be replaced for a new one
when its wear to 4/5 the thickness of original. Anastomotic clearance between gear teeth of worm wheel and
helical tooth of worm shall be 0.15mm～0.30mm, with three teeth bearing force. Manually operate the jigger
neatly after combining worm wheel and worm.
4) Overhaul of sliding block
Suitable tightening force of two sliding blocks and journal of tension shaft shall be 0.0mm～0.01mm,
and suitable clearance between slide of sliding block and guide plate shall be 0.5mm～1mm, the max
adjusting range of sliding block shall not be less than 300mm.
1） Overhaul of shaft

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6) Overhaul of chain wheel
 Gear teeth symmetry shall be synchronized when assembling two pairs of chain wheels, and it shall
be smooth and no burr in vertical slot, and both sides of clearance between vertical slot and standing chain
ring shall be 3 mm～5mm respectively, while length of flute between two contiguous vertical slots shall be
about 10 mm～20mm longer than horizontal chain ring.
 There shall not be ring rib layer deeper than 0.5mm and crack on the surface of shaft sleeve, and
tightening force of shaft sleeve shall be 0.03mm～0.05mm, with no defect of abrasion and partial grinding at
both ends of shaft sleeve that will cause axial distance of bear to be greater than allowable value. End face
with boss of shaft sleeve and interface between inner ring of bear shall guarantee uniform contact.
 Boss of transparent cover on both sides of chain wheel shall insert into chain wheel entirely and be
uniformly combined with outer ring of bear, outer side of transparent cover and interface between chain
wheel and hub shall guarantee: the degree for uniform contact with any relatively view.
 Assembly interface between transparent cover’s outer side and hub and screw hole on chain wheel
shall be cleaned up and grazed. There shall not be groove mark on surface of the circle in chain wheel.
Suitable clearance between transparent cover on both sides and shaft shall be 0.5mm～1mm.
 Retaining ring shall cling to inner ring of bear, and height of snap ring is 1/2 to 2/3 the thickness of
bear’s inner ring generally.
 Tension roller shall adjust chains to no over-lap.
7.3.2.3 Pilot run of submerged chain conveyor
1 Contact with operation to return switching sequences after finishing work, and contact with power
supply after inspection.
2 Dynamo shall supply power to test rotation direction after assembling submerged chain conveyor.
After confirming rotation direction and when rotation direction of no-load running dynamo matches, cut off
the power to connect the coupling bolt or install drive belt.
3 Test run each bear and rotation part, and rotation shall be flexible and no clamping stagnation.
4 Working temperature of bear shall be stable, rolling bear shall be lower than 80 degree and rolling
sounds normal.
5 Vibration shall be less than 0.05mm generally; With no chain skipping.

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6 End working sheet and hand over operation after test run.
7.4 Daily maintenance and troubleshooting
7.4.1 Submerged conveyor fault cause and troubleshooting
No. Fault Cause Troubleshooting
1 Uneven tension force on both
1 Adjust the tensioning device
sides
1 Off the chain 2 Align the driving shaft again
2 Driving shaft skew
3 Replace the chain
3 Chain abrasion
1 Scraper broken 1 Shutdown inspection and troubleshooting
2 Chain scission
2 Scraper deformation 2 Replace the deformed scraper
1 Restart after inspection and troubleshooting
1 Over-current protection action
3 Main shaft stalling 2 Replace insurance pin after inspection and
2 Insurance pin broken
troubleshooting
1 Driving, tension, and guide
1 Readjust
wheel are not in a vertical plane
2 Readjust tensioning
4 Chain running deviation 2 Uneven tension force
3 Find the corresponding section and
3 The chain length deviation is
exchange the left and right
too big
1 Dirty oil filter net
1 If the fault above occurs, never start the
Hydraulic driving device fault 2 Low fuel tank oil level
5 hydraulic driving device
alarm 3 High oil temperature
2 Shutdown for processing
4 Low pressure of oil pump
1 Submerged conveyor water
temperature exceeds the limit 1 Check the hydrating situation, judge it is
value water inlet valve fault or temperature switch
2 Submerged conveyor speed fault
switch fault. The submerged 2 Determine whether broken chain occurs or
Submerged conveyor fault
6 conveyor starts, but speed disk not
alarm
does not move 3 Jog backward move, restart if checked to be
3 High load or chain block in normal
submerged conveyor 4 If the situation is normal, shutdown for
4 Tension device high-high level processing immediately
alarm
7.4.2 Thickener fault cause and troubleshooting

1 Big mortar concentration
1 Accelerate plasma discharge
2 Driving part damage or
2 If it cannot recover in short time, and the
blockage
1 Thickener overload current still have increase trend, stop inletting
3 Rake tine and rack damage and
plasma
deformation and friction with
3 Empty the thickener for internal processing.
hard material on at pool bottom

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4 Foreign matters falling into
pool and friction with rake tine
1 Overhaul motor
1 Poor contact of carbon brush
2 If the thickener shutdown, stop inletting
Instant swing or tripping of and slip ring, motor two-phase
2 plasma
thickener motor current running
3 Check the protection system, and replace
2 Relay misoperation
the damaged original parts
3 Rake rack and tine failure Corrosion and abrasion Replace the rake rack and tine
1 Lack of oil or poor oily 1 Add oil or replace new oil
4 Reducer heating or noise 2 Improper meshing of gear 2 Adjust gear meshing clearance
3Serious gear abrasion 3 Replace gear
1 Lack of oil or poor oily
1 Add oil or replace new oil
2 Wrong horizontal axis
5 Bearing running hot 2 Shutdown for adjustment or reinstallation
installation
3 Replace bearing
3 Bearing abrasion or fracture

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8. Appendix:
8.1 General precaution for common overhaul

1 When removing rust bolts, it can be drenched in kerosene or loosening agent firstly.
2 When the coupling needs heating during removal, it shall be heated outward to the around evenly. If
the shaft has been heated, the coupling cannot be taken out, at this point, stop heating and coupling removal
work, make the shaft and coupling cooling down to environment temperature, then reheat to remove the
coupling.
3 It is better to remove bearing with special tools. When adopt copper hammer method, pay attention to
even forcing and never only beat one point or one side which may cause bearing skew, shaft diameter or
bracket damage.
4 When installing coupling or heating bearing, attention that the heated body shall be uniformly, heating
temperature shall be controlled within 120℃. It is best to use the oil-immersed on bearing heat.
5 Never beat with hammer directly to install coupling or bearing. When needing beating, there shall be
no end face and edge deformation formed at the parts beating by hammer which may influence the
installation.
6 When installing the shaft key, pay attention to the plug shaft key into the shaft groove tightly. Key can
freely move in and out of the race. The length of the key should be 0.01mm shorter than slot length. The top
clearance of keys and the race shall be 0.4mm～0.5mm.
7 The jointing side shall be sealed with sealant. Pay attention not to touch the sealing side wirongly
when fastening.
8 Sealant use requirement
Pretreatment: remove the oil dirt, water, dust and rust on the sealing surface. During exclusive use, the
clearance between two sealing sides shall be greater than 0.1mm.
Coating: coating thickness depends on the machining accuracy, smoothness, and the size of the gap and
other specific circumstances of sealing surface. It normally coats 0.06 mm ～0.1mm thick on both sealing
end side.
Drying: solvent liquid sealant should be dry, drying time depends on the used solvent type and thickness
of the coating, normally it is 3 min～7min.
9 Thread requirement: the internal and external thread on parts shall be complete, which shall be free of
tooth sliding and the mechanical damage of large area and thread falling off phenomenon.
8.2 Low voltage motor maintenance manual
8.2.1 Major overhaul item of low voltage motor
1 Clean the motor surface dirt and motor disassembly;
2 Motor stator coil overhaul, measure the grounding phase insulation of stator coil, measure the cable
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insulation, and test the winding DC resistance;

3 The motor rotor inspection and surface cleaning;
4 Bearing cleaning maintenance replace the damaged bearing;
5 Motor refitting, free load startup, and record test data;
6 Load switch cable inspection, the drawer switch inspection, control circuit and local control box
inspection.
7 Take motor trial operation, and record the motor starting, free load and operating current and measure
the motor vibration;
8 Fill in the maintenance records.
8.2.2 Minor overhaul item of low voltage motor
1 Clean the motor surface dirt;
2 Motor terminal box winding lead and connecting bolts inspection and fastening;
3 Measure the stator coil grounding insulation;
4 Control circuit and local control box inspection;
5 Load cable inspection;
6 Drawer switch inspection;
7 Take motor power-on trial operation, and record the motor starting current and operating current;
8 Measure the motor vibration and temperature;
9 Fill in the inspection data.
8.2.3 Overhaul technology and quality standard
8.2.3.1 Preparation before motor overhaul
1 Before overhaul, they must confirm working sheet has been processed;
2 Prepare tools, materials, spare parts, notebooks, etc.
8.2.3.2 Motor disassembly:
1 Disassemble the external wiring of motor
 Remove the motor power cord, and make corresponding marks.
 Cable wire three-phase short circuit grounding.
 Measure coil insulation, DC resistance.
2 Motor disassembly
 Remove the upper clutch on motor shaft with stroke and take out the shaft key.
 Remove the fan cover, positioning spring card, use special tools to unload the fan on the shaft.
 Remove the small cover on both ends of the motor, and make corresponding marks of “negative” or
“reverse”.
 Remove the big cover on both ends of the motor, and make corresponding marks.

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 Pull out the rotor.

 Caution:
Take out the rotor, pay attention to monitor stator air clearance on both ends.
When pulling out the rotor without touching the end coil.
8.2.3.3 Motor overhaul
1 Stator cleaning overhaul
 Purge the stator core with dust blower and clean the dirt and clingage at the coil end with wrapping
cloth, charged cleaner and wipe out with dry cloth.
 Check the coil insulation is without inflation and overheating, discoloration, gummosis, deformation,
damage phenomenon and binding wire is tight.
 Check that the iron core compression screw is not loose, and silicon is close without rust, and the slot
wedge is free of discoloration, withered, fracture, etc.
 Check that the architrave leading wire insulation is good, and free of discoloration, leakage and broken
strand, fracture phenomenon.
 Big covers on both ends shall be free of damage, deformation, crack and burr.
 Measure motor insulation and DC resistance and conform to the standard.
2 Rotor clean and inspection
 Clean the various parts of the rotor.
 Appearance inspection for that the squirrel-cage bar and short circuit ring shall be free of disordering,
fracture, loose and crack phenomenon.
 Check that the shaft and rotor be fastened as a whole and free of breakage or abrasion.
 Check to weld the rotor and fan firmly, riveting fastening blade shall be free of distortion and crack
phenomenon.
 Remove the old bearings on both ends.
 Check that the journal shall be in good condition and clean, and free of rusty spot and burr.
 New bearing inspection.
Quality standard:
Appearance inspection, bearing internal and external track is without obvious defects such as pitting,
corrosion, and with flexible rotation, no noise, keep the frame in good condition, without direct contact with
the inner and outer ring.
Measure the bearing clearance which shall conform to the standard requirements.
Measure the clearance of bearing and shaft, bearing and end cover connection shall be appointed
standard requirements.
 Bearing assembly

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Processing method:
Put in the small cover in both sides, heat the bearing to 100℃ (not exceed 110℃) with bearing heater
and put it onto shaft.
Push the bearing in position quickly.
Clean up new bearing and wipe it up with white sand strip.
Add lubricating oil unto bearing housing.
8.2.3.4 Motor assembly
1 Inspection before assembly.
 Quality standard:
Clean up the motor rotor and stator, after finish inspection, each part works normally and the device
shows true color.
Bearing testing and assembly conform to the standard.
Motor stator insulation and winding DC resistance measurement conform to the requirements of the
standard, (fill in Table 2).
Table 3～6
 Technical requirements:
The coupling wheel disassembling must use heating method, and heating temperature shall not to exceed
250℃.
Bearing installation uses the hot pack method and its temperature shall not exceed 110℃, during heating,
adopt oil or electric heating, but forbid direct heating of flame.
After the motor assembly, fasten the screw tightly, and manual jigger is flexible.
2 Motor assembly
 Get through the rotor, pay attention to the rotor air gap, don't touch the wound coil and iron core.
 Assemble the end cover of both side of motor and the small cover of bearing housing.
 Install recidivating load side fan and fan cover.
 Reassemble the coupling wheel.
3 The motor is in place and connect the external connection wire.
 Lift motor to be in position.
 Check that motor outgoing line is firm, wiring according to the signs, and fasten the screw.
 Connect the case grounding line.
8.2.3.5 Motor trail operation
1 Contact the operation to measure the motor insulation resistance and power on.
2 Free load operation and make records.
8.2.3.6 Finishing work

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1 Contact related personnel to connect maintenance section.

2 Clean-up the field, summarizes the working sheet.
8.3 Valve maintenance manual
8.3.1 Butterfly valve overhaul technology and standard
The outside diameter design of the piece type valve is easy to use flange bolts for valve centering.
Control parts are three type which including manual pull fantasy, manual gear box, electric drive.
8.3.1.1 Installation sequence
Close the valve and put it between the flanges→ insert flange bolts and tighten it evenly→ through the
valve control system to check valve switch flexibility.
8.3.1.2 Removal sequence
Confirm the pressure in pipe has been discharged→ lose the valve→ remove the flange bolts and lift out
of the valve.
8.3.1.3 Valve disassembly
At first, fully open the valve→ unscrew the fastening screw of actuator/handle→ remove the
actuator/handle→ remove the blowout fracture bolt→ pull out of the upper shaft, spring coil, and the upper
guide sleeve from the valve body→ remove the shaft to keep pin and pull out the lower shaft from the valve
body→ push out the valve plate from valve seat without inclining→ remove the guide sleeve from valve
plate→ remove the valve seat from valve body.
8.3.1.4 Valve assembly
Before the valve assembly, brush the grease lubrication evenly and corrosion protection on the external
diameter of ring seat, inner surface of valve rod hole, upper and lower shaft and shaft fixed bolts. When
replace the shaft, use the reaming on the valve plate for positioning.
8.3.1.5 Overhaul quality standard
1 Rubber lining is in good condition without abrasion, if it is with serious abrasion, it cannot play a role
of cutting off, replace the rubber lining or valve.
2 Valve moves flexibly and cannot be unsmooth. Replace the door plank if with deformation.
3 The valve closed statues shall ensure tightness.
8.3.2 Diaphragm valve overhaul technology and quality standard
8.3.2.1 Valve installation
1 Adjust the centering, connect the pipe with proper support, to prevent the uneven stress and avoid
installing the valve at large bending.
2 The applying pressure of valve bolts must be in conformity with relevant torque standards.
3 Before and after installation, all glass lining body shall take discharge test.
4 Before the valve debugging, ensure to clean up the rust, metal welding bead in the pipe, so as not to

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damage the seating surfaces.

8.3.2.2 Remove valve
1 Before the removal of valve, confirm the valve and connection pipeline system pressure has been
released, the temperature drops.
2 Remove the flange bolts and lift out the valve.
1 Operate the switch valve, and prohibit using a wrench or plier to act on hand wheel to increase torque
for switch operation, so as not to damage the diaphragm.
2 It is strictly prohibited to close or open the valve too greatly.
3 Larger work pressure assembling gear drive and electric actuator, but its speed is strictly restricted;
valve switch load is centralized on the diaphragm bolt, continuous close and open may cause bolt loosening
which should be tighten promptly.
8.3.3 Non-return valve overhaul technology and standard
8.3.3.1 Non-return valve removal and disassembly.
1 Place the non-return valve on the ground with the outlet side upward, to prevent the flange side.
2 Loosen the automatic locking nut and lock washer of valve plate.
3 Push the valve plate to open position, loosen the automatic locking bolt of valve plate, and remove the
valve plate together with the O-ring and stainless steel gasket.
4 Loosen the bracket bolts and stainless steel gasket, remove the connecting rod and spring.
5 Check the sealing side of valve seat and valve plate; repair the minor scratches or dents through grind
door.
6 Check the O-ring of valve plate, replace if damaged.
8.3.3.2 Reassembly of non-return valve.
1 Thoroughly clean all parts.
2 Brush the nuts, bolts and o-rings with oil for lubrication.
3 Place the valve shell on the ground as the export side up.
4 Install connecting rod, spring, bolts and gaskets portfolio to the bracket of valve body.
5 Install the valve plate, gasket, bolt, washer and nut, o-ring on the connecting rod. Lock the bolt and
nut.
8.3.4 Common fault and troubleshooting
Common fault Cause Troubleshooting
Packing or O-shaping Loose packing; Tighten the pressure screw evenly;
leakage Packing or O-shaping leakage failure. Replace packing or O-shape ring.
Sealing surface leakage Dirty sealing surface; 1. Remove dirt on the surface of the seal;
Damaged sealing surface. 2. Repair or replace the sealing surface.
The disc can't turn smoothly 1. Packing is too tight; 1. Loosen the packing rightly;

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Common fault Cause Troubleshooting

2.Paccking cover distortion; 2. Adjust the packing cover;
3. Shaft is not straight; 3. Adjust the shaft;
4. Handle connection is too loose. 4. Replace the pin.
8.4 Water pump maintenance manual

8.4.1 Overhaul content
8.4.1.1 Minor overhaul item
1 Replace the packing seal.
2 Check and clean the bearing, bearing box, oil baffle ring, water retaining ring, oil mark, etc., and
adjust bearing clearance.
3 Check and repair alignment situation of coupling and drive machine with pump.
4 Deal with the common defects occurs during operation.
5 Check and repair the cleaning water, sealing and lubrication system.
8.4.1.2 Major overhaul item
1 Including items of minor overhaul.
2 Check and repair the mechanical seal.
3 Disassemble and check parts abrasion, corrosion and erosion condition. Take nondestructive flaw
detection for pump shaft, impeller when it is necessary
4 Check and clean the bearing, oil seal, etc., measure and adjust the bearing oil seal clearance.
5 Check and measure the circular runout and clearance of each part of rotor, and do dynamic balance
verification when it is necessary.
6 Check and calibrate of shaft straightness.
7 Measure and adjust the rotor axial momentum.
8 Check the dislocation condition of the pump body, foundation, anchor bolt and import and export the
flange, to prevent the additional stress on pump body, when it is necessary to piping.
8.4.2 Overhaul and quality standard
8.4.2.1 Preparation before disassembly
1 Hold the pump operation condition and prepare for the necessary drawings and information.
2 Prepare the overhaul tools, measuring tools, lifting equipment, parts and materials.
3 Deal with working sheet, cut off the power and equipment connection with system, empty the medium
inside the pump to achieve the equipment safety and overhaul condition.
8.4.2.2 Disassembly steps
1 Loosen anchor bolts of motor, remove the motor, tidy up the motor pitch screws bottom pads and
make records.
2 Firstly loosen the fastening bolts of pump cover and pump body, remove the rotor from the pump body
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with jacks screw.

3 Loosen the nuts in front of impeller and remove the impeller with puller.
4 Remove the pump cover, shaft sleeve and mechanical seal, loosen the mechanical seal bolts to
disassemble mechanical seal.
5 Take out coupling with puller.
6 Loosen bolts on both ends of the bearing housing, remove the end cover on both sides, and take out the
rotor part with a special tool.
7 Take out bearing with puller or special tools.
8.4.2.3 Cleaning and inspection
1 Choose diesel as cleaner (more security than gasoline).
2 Mechanical seal cleaning and inspection; moving ring and static ring end face is damaged; spring
floatability; auxiliary seal aging and damage.
3 Clean and inspect the impeller; whether there is abrasion on sealing ring, choose measuring implement
to measure the connection clearance.
4 Check and measure shaft bending.
5 Bearing inspection and clearance measurement.
6 Inspection of other parts.
7 Inspection of each auxiliary sealing element.
8.4.2.4 Reassembly inspection and measurement
1 Reassemble as the reverse sequence of disassembly.
2 Bearing installation give preference for temperature difference method, the heating temperature does
not exceed 100℃~120℃, cooperating with outer diameter and inside caliper, to measure whether the bearing
can be reassembled.
3 Install the assembled rotor on V-shaped iron for measurement, beat on three points which aims to
ensure that there is no friction between dynamic and static impeller, ensure good mechanical seal, and ensure
concentricity of pump and motor at the coupling.
4 Install one side cover, assemble the rotor into the bearing housing with specialized tools.
5 Coupling installation shall adopt temperature difference method, heating of oil cannot exceed its flash
point, heating temperature of gas welding does not exceed 400℃.
8.4.2.5 Coupling alignment.
1 Mop up the machine seat and motor bottom.
2 Place the motor on the frame and check whether there is clearance with a feeler, use feeler gauge to
measure the thickness of the gaskets, to ensure there is no deformation when fastening anchor.
3 Use the feeler for coarse finding.

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4 Use formula to calculate the added shim thickness.

5 Use a dial indicator fine alignment.
8.4.3 Trail operation
8.4.3.1 Turning machine for alignment manually before trail operation until be no friction, abnormal noise
and vibration.
8.4.3.2 Contact for trail operation and power on as regulated.
8.4.3.3 Centrifugal pumps are strictly forbidden to dead load test, it shall take on-load test according to the
operating instructions.
8.4.3.4 For the forced lubrication system, oil bearing temperature rise shall not exceed 28℃, the
temperature of bearing metal shall be less than 93℃; for oil ring lubrication or splash lubrication system, the
temperature rise of oil pool should not be exceeded 39℃, and the oil pool temperature shall be lower than
82℃.
8.4.3.5 Keep smooth operation, no noise, sealing oil and lubricating oil system, cooling water work well,
pump and accessory pipeline are free of leakage.
8.4.3.6 Control the flow, pressure and current is within the prescribed scope.
8.4.3.7 The sealed media shall be free of any leakage.

Page 71 of 71

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A 2013.10.

20 FIRST SUBMISSION LiuXing LiWenke ChenJinghai

APPROVED ChenJinghai CHECKED LiWenke

7. Operation specification of slag discharging system ....................................................................................... 49

Maintenance Manual on Ash Handling & Flue Gas Desulfurization

1.1 Main engine device model

General chemical reaction quotations are stated as follows,

Maintenance Manual on Ash Handling & Flue Gas Desulfurization

Maintenance Manual on Ash Handling & Flue Gas Desulfurization

2.1 Flue gas desulfurization (FGD) system performance

2.1.2 Flue gas desulfurization (FGD) system supplied seawater parameter

2.1.3 Flue gas desulfurization (FGD) system performance requirements

Maintenance Manual on Ash Handling & Flue Gas Desulfurization

2.2 Equipment specifications

Maintenance Manual on Ash Handling & Flue Gas Desulfurization

Name Specifications Quantity

3. Maintenance and overhaul of flue gas desulfurization (FGD) system devices

FGD system device is divided into three levels of A, B, C,

class A and B or regular rolling overhaul items.

Maintenance Manual on Ash Handling & Flue Gas Desulfurization

System Level C overhaul

Maintenance Manual on Ash Handling & Flue Gas Desulfurization

System Level C overhaul

1) Dismantle coupler and 1) Dismantle coupler 1) Dismantle coupler

Maintenance Manual on Ash Handling & Flue Gas Desulfurization

System Level C overhaul

Maintenance Manual on Ash Handling & Flue Gas Desulfurization

System Level C overhaul

3.2 Main equipment maintenance process and quality requirement

Maintenance Manual on Ash Handling & Flue Gas Desulfurization

Maintenance Manual on Ash Handling & Flue Gas Desulfurization

1) Calibrate motor magnetic

Maintenance Manual on Ash Handling & Flue Gas Desulfurization

Maintenance Manual on Ash Handling & Flue Gas Desulfurization

Maintenance Manual on Ash Handling & Flue Gas Desulfurization

Maintenance Manual on Ash Handling & Flue Gas Desulfurization

4. Dirt catcher equipment maintenance and overhauling

4.1 Electric precipitator equipment overview

Maintenance Manual on Ash Handling & Flue Gas Desulfurization

Item Feature and specification Unit Remarks

Item Feature and specification Unit Remarks

4.3 Safety tips (precautions)

Maintenance Manual on Ash Handling & Flue Gas Desulfurization

door opening isn’t closed.

Maintenance Manual on Ash Handling & Flue Gas Desulfurization

Maintenance Manual on Ash Handling & Flue Gas Desulfurization

Maintenance Manual on Ash Handling & Flue Gas Desulfurization

Maintenance Manual on Ash Handling & Flue Gas Desulfurization

Maintenance Manual on Ash Handling & Flue Gas Desulfurization

Maintenance Manual on Ash Handling & Flue Gas Desulfurization

No. Fault phenomena Main causes Handling methods

Maintenance Manual on Ash Handling & Flue Gas Desulfurization

No. Fault phenomena Main causes Handling methods

Maintenance Manual on Ash Handling & Flue Gas Desulfurization

No. Fault phenomena Main causes Handling methods

Maintenance Manual on Ash Handling & Flue Gas Desulfurization

No. Fault phenomena Main causes Handling methods

Maintenance Manual on Ash Handling & Flue Gas Desulfurization

5. Pneumatic ash conveying equipment maintenance and overhauling