ABB CE HP943 PULVERIZER

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ABB CE HP943 PULVERIZER
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INSTALLATION,OPERATION AND MAINTENANCE
TABLE OF CONTENTS
HP PULVERIZER INSTALLATION .................................................................. TAB
Pulverizer Description ........................................................................... Part 1
Protection and Preservation of Pulverizer Componenes ......................... Part 2
Installation Procedures .......................................................................... Part 3
HP PULVERIZ OPERATION ........................................................................... TAB
Principles of Operation .......................................................................... Part 1
Pulverizer OperatingProcedures ........................................................... Part 2
Lubrication Systems .............................................................................. Part 3
Pulverized Coal Fineness - Adjustment and Testing ............................. Part 4
HP PULVERIZER MAINTENANCE ................................................................... TAB
General Maintenance Procedures ......................................................... Part 1
General Disassembly ............................................................................ Part 2
General Reassembly ............................................................................. Part 3
Pulverizer Component Servicing ........................................................... Part 4
HP PULVERIZER ILLUSTRATIONS .............................................................. TAB
ENGINEERING DRAWINGS ........................................................................... TAB
Contract Drawings .................................................................................
Pulverizer Drawings .............................................................................
Maintenance Tool Drawings ..................................................................
I
II
III
IV
V
Part 1
Part 2
Part 3
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TABLE OF CONTENTS
PULVERIZER DESCRIPTION
PART 1
PULVERIZER DESCRIPTION ................................................................................. 1-1
PROTECTION AND PRESERVATION OF PULVERIZER COMPONENTS
PART 2
INTRODUCTION .......................................................................................................
GENERAL STORAGE REQUIREMENTS ..............................................................
Storage Types ...............................................................................................
Minimum Storage Requirements ................................................................
Component Storage .......................................................................................
INSTALLATION PROCEDURES
2-1
2-2
2-2
2-2
2-4
INTRODUCTION .......................................................................................................
PULVERIZER COMPONENTS ......................................................................................
GENERAL ASSEMBLY ............................................................................................
SOLE PLATE AND MOUNTING PLATE ALIGNMENT AND GROUTING ........
Pulverizer ........................................................................................................
Motor ...............................................................................................................
MILLSIDE AND LINER ASSEMBLY ......................................................................
BOWL, BOWL HUB AND VANE WHEEL ASSEMBLY ...................................
SEPARATOR BODY .............................................................................................
SEPARATOR TOP ASSEMBLY ..........................................................................
MILL DISCHARGE VALVES AND MULTIPLE PORT OUTLET ASSEMBLY .......
OUTLET VENTURI AND VANES ASSEMBLY ..................................................
INNER CONE WITH LINERS ..............................................................................
JOURNAL OPENING COVER WITH SPRING ...................................................
GEARBOX ASSEMBLY INSTALLATION ............................................................
BOWL HUB SKIRTS AND INNER AIR SEAL INSTALLATION .....................
SECURING THE GEARBOX ................................................................................
CLEARANCE AIR SEAL ......................................................................................
PULVERIZER MOTOR ..........................................................................................
JOURNAL INSTALLATION ...................................................................................
Journal Assembly Installation ....................................................................
Journal Head Assembly Installation .......................................................
Journal Roll And Shaft Assembly Installation .....................................
TRUNNION SHAFT,JOURNAL SPRING SEAL AIR ..........................................
FEED AND FUEL PIPING ASSEMBLY .............................................................
DISCHARGE VALVE LIMIT SWITCH SET-UP ..................................................
CONTROLS ............................................................................................................
FINAL ADJUSTMENTS: JOURNAL SPRING PRELOADING PROCEDURE,
JOURNAL ROLL-RING CLEARANCE, JOURNAL SPRING POSITION
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ABB CE TYPE HP943 PULVERIZER - INSTALLATION
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TABLE OF CONTENTS
Part 1
PULVERIZER DESCRIPTION
TITLE
PAGE NO.
PULVERIZER DESCRIPTION ................................................................ 1-1
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LIST OF FIGURES
TITLE
FIGURE NO.
HP Pulverizer .........................................................................................
HP Pulverizer Coal and Air Flow ......................................................
1-1
1-2
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PART 1 - PULVERIZER
DESCRIPTION
PULVERIZER DESCRIPTION
ABB Combustion Engineering has developed a series of pulverizers which
grind and dry coal in power plants through out the world. The grinding
surface in the pulverizer resembles a deep dish or bowl. Therefore the
name"Bowl Mill" has been adopted to refer to this piece of equipment.
The Pulverizer consists of:
1. The gearbox, which is driven by an electric motor, is directly connected
to the bowl hub. A planetary gear arrangement provides the proper
reduction between the motor and the bowl hub to obtain the desired
bowl speed.
2. The millside, its liners and air inlet (Refer to Figure 1－1) surround the
bowl and the bowl hub and support the separator body. Air for
transporting and drying the coal enters through the air inlet,and is
directed upward around the bowl.
3. The "bowl" is the table upon which the coal is crushed. Material to be
ground is admitted to the pulverizer and deposited near the center of the
rotating bowl.
4. The vane wheel assembly, which is attached to the bowl, manages the
coal/air mixture within the grinding zone of the pulverizer by uniformly
distributing the transport air through the bowl O.D. and inner cone/
separator body annulus.
5. Three independent, spring loaded journal assemblies are suspended
from the separator body and overhang the bowl. The journal assembly
rolls are free to rotate, and do so, when the coal being pulverized fills
the space between them and bowl.
6. The separator body. deflector liners and separator top with attached
deflector assemblies and the inner cone and classifier, contain the
material after it is pulverized. The separator body, deflector liners and
separator top direct the material and transport air up through the
deflector assemblies where larger particles of material are separated
from the transport air and returned to the bowl for further grinding
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7. The outlet venturi and multiple port outlet assembly separates
the flow of material and transport air into four (five or six)
separate, equal streams.
8. The pulverizer discharge valve assembly is mounted on top of
the multiple port outlet assembly. The four valves, which make
up the assembly, are used to isolate the pulverizer from an
operating furnace during a unit start-up and when the idle
pulverizer contains coal. They are also used (in conjunction with
coal line valves) to isolate the pulverizer for maintenance.
The illustrations used in the pulverizer manual are included to
supplement and clarify written information, the components
pictured are typical of those used on the ABB CE HP Series of
pulverizers. They may not picture all of the pulverizer parts as they
actually exist on your equipment. The value of the descriptive
material, however is not affected in any way.
1-2
4
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TABLE OF CONTENTS
PROTECTION AND PRESERVATION OF PULVERIZER COMPONENTS
TITLE
PART 2
PAGE NO.
INTRODUCTION ....................................................................................................
GENERAL STORAGE REQUIREMENTS .........................................................
Storage Types ...............................................................................................
STORAGE TYPE B .....................................................................................
STORAGE TYPE C .....................................................................................
STORAGE TYPE E .....................................................................................
Minimum Storage Requirements ..................................................................
MAJOR SUBASSEMBLIES .........................................................................
BOXED OR BUNDLED ITEMS ....................................................................
TOOLS AND FIXTURES ................................. ............................................
Component Storage .......................................................................................
GEARBOX ASSEMBLY ......................................................... .....................
OUTLET VENTURI AND FEED PiPE ASSEMBLY, MULTIPLE PORT
OUTLET AND OUTLET PLATE .........................................................
MILL SIDE AND SEAL AIR HEADER ASSEMBLY .......... ...........................
SEPARATOR BODY ASSEMBLY ...............................................................
JOURNAL HEAD AND TRUNNION SHAFT ASSEMBLY ...........................
JOURNAL OPENING COVER ASSEMBLY ................................................
SEPARATOR TOP ASSEMBLY ..................................................................
PULVERIZER DISCHARGE VALVE/MULTIPLE PORT OUTLET
ASSEMBLY ........................................................................................
INNER CONE OR INNER CONE AND CERAMIC LINER ASSEMBLY ......
JOURNAL SHAFT ASSEMBLY ..................................................................
GEARBOX LUBRICATION UNIT, OIL COOLERS, GEAR BOX
ACCESSORIES, OIL HEATERS ............. ..........................................
SOLE PLATES AND MOUNTING PLATES ................................................
MISCELLANEOUS FASTENERS ........................... ....................................
BOWL, BOWL HUB AND VANE WHEEL ASSEMBLY .... ...........................
SEAL AIR SYSTEM PIPING ............................................................. ..........
CENTER FEED PIPE UPPER AND INVERTED CONE ....... ......................
COUPLING ASSEMBLY ................................. ............................................
LUBE OIL PIPING .......................................................................................
MOTOR COUPLING GUARD, BOWL HUB CLEARANCE, AIR SEAL AND
GUARD, COAL SAMPLING FITTINGS, THERMOWELLS,
BULL RING SHIMS ............................................................................
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TABLE OF CONTENTS (Continued)
PROTECTION AND PRESERVATION OF PULVERIZER COMPONENTSPART 2
TITLE
PAGE NO.
DIFFERENTIAL PRESSURE CONTROLLER ...................................... 2-7
BOWL HUB UPPER AND LOWER SKIRT ASSEMBLIES,SCRAPER AND
GUARD ASSEMBLIES, AND JOURNAL SKIRT ASSEMBLIES
2-8
WATER PIPING AND NOZZLE ASSEMBLIES .................................... 2-8
INNER CONE CERAMIC LINERS .................................. .................... 2-8
MOTORS .............................................................................................. 2-8
BOWL HUB HOISTING FIXURES, JOURNAL TILT-OUT COMPONENTS,
GEARBOX ALIGNMENT FIXTURES ........................................ 2-8
COAL SAMPING DEVICE, OIL DIP STICK, SPECIAL TOOLS ... ........ 2-8
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PART 2 - PROTECTION AND
PRESERVATION OF
PULVERIZER COMPONENTS
INTRODUCTION
The pulverizer is too large to be shipped assembled. As a result, it is broken
down into many subassemblies and loose components. If pulverizer components will require field storage (for up to two years), the following specifications should be followed.
NOTE
Components, when received, should be stored in accordance
with ABB Combustion Engineering's, Mechanical Design Standard Number 18-79 (Index No. 11.5.1).
The coatings, oils and plugs referred to in these procedures are initially
applied in the shop. They should be checked and maintained in the field as
required.
USE CARE WHEN HANDLING ASSEMBLIES WHICH
CONTAIN CERAMIC LINERS. THE LINERS MAY
CRACK IF AN ASSEMBLY IS HANDLED ROUGHLY
NOTE
Cosmoline No. 1058 (E.F. Houghton & Co., Valley Forge, PA)
and grease are used many places for preservation. These
coatings must be maintained during the storage period. When
the component is being readied for assembly, the
Cosmoline/grease must be removed with a petroleum based
solvent.
NOTE
Plastic tapered plugs, plastic tapered caps, plastic pipe thread
protectors, plastic valve flange protectors and plastic web
sleeving are used in many locations. They are made of low
density polyethylene unless otherwise specified.
2-1
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GENERAL STORAGE
REQUIREMENTS
Storage Types
Three types of storage must be employed when storing pulverizer
components.
STORAGE TYPE B
Store indoors within an insulated building, upon a concrete slab or
metal pallet shelving. The space shall include lighting and environmental controls for heating.
STORAGE TYPE C
Store in weather-tight indoor areas with no provision for heating and
with natural lighting. Floors may be compacted earth. Material shall be
stacked off the floor upon dunnage with sufficient room for visual
inspection. Make provision against add heating, if required, during
certain periods shall be included.
STORAGE TYPE E
Consists of field storage of components positioned on dunnage, so as
to provide for drainage, inspection and maintenance. Protective
coatings, seals and caps shall remain in placed and be maintained.
Provisions to add covering, when dictated by the local environment,
shall be included.
Minimum Storage
Requirements
MAJOR SUBASSEMBLIES
The storage type for each of the normal major subassemblies is as
follows:
Storage Type
(Minimum)
1. Outlet venturi and vane assembly
E
2. Millside and seal air header assembly
E
3. Separator body assembly
E
4. Journal head and trunnion shaft assembly
C
5. Journal opening cover assembly
C
6. Separator top assembly
E
7. Inner cone (and ceramic liner) assembly
E
8. Journal shaft assembly
C
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MAJOR SUBASSEMBLIES (continued)
9.Gear box lubrication unit
Storage Type
(Minimum)
C
10.Gear box assembly (Refer to Manufacturer's instructions)
C
11.Bowl, bowl hub, and vane wheel assembly
E
12.Mill discharge valve and multiple port outlet assembly
C
BOXED OR BUNDLED ITEMS
The storage type for the following items, which may be bundled or boxed, is
as follows:
Storage Type
(Minimum)
13 Sole plates, and mounting plates
C
14. Seal air components (pulverizer and discharge valve)
C
15. Center feed pipe - upper
E
16. Inverted cone
E
17. Bowl hub clearance air seal and guard
C
18. Bowl hub upper and lower skirt assemblies
C
19. Scraper and guard assemblies
C
20. Mill motor coupling
C
21. Miscellaneous fasteners
B
22. Motor coupling guard
C
23. Lube oil piping
C
24. Water piping and nozzle assemblies
C
25. Gear box accessories
C
26. Journal skirt assemblies
C
27. Differential pressure controller
B
28. Thermowells
C
29. Aspirating (coal sampling fittings)
C
30. Bull ring shims (extra)
C
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TOOLS AND FIXTURES
31.
32.
33.
34.
35.
36.
37.
Coal sampling device
Oil dip stick
Special tools
Bowl hub hoisting fixtures
Journal tilt-out components
Spring preload components
Gearbox alignment fixtures
Storage Type
(Minimum)
B
B
B
C
C
B
C
Component Storage
GEARBOX ASSEMBLY (Storage Type C)
The gear box assembly is to be placed on timbers and preserved as per
vendor's specifications. Refer to VENDOR'S MANUAL for detailed instructions.
OUTLET VENTURI AND FEED PIPE ASSEMBLY.MULTIPLE PORT OUTLET
AND OUTLET PLATE (Storag Type E)
Place the components on timbers with the axis of the feed pipe horizontal.
Coat all exposed machined surfaces and the threaded holes with CosmoIine
No. 1058. Plug tapped holes with plastic tapered plugs. Securely cover the
assemblies with clear heavy gauge plastic.
EXERCISE CARE WHEN HANDLING THESE ASSEMBLIES.
ROUGH HANDLING MAY CRACK CERAMIC LINERS.
MILLSIDE AND SEAL AIR HEADER ASSEMBLY (Storage Type E)
Place the assembly on timbers. Coat all of the exposed machined surfaces.
including tramp iron spout flange, air inlet flange, millside access door flanges,
tapped and dowel pin holes with Cosmoline No. 1058. Plug all of the tapped
and dowel pin holes with tapered plugs.
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SEPARATOR BODY ASSEMBLY (Storage Type E)
Place the assembly on timbers and orient it as if it is installed on the
pulverizer. Support must be to the lower flange, not the deflector liners which
protrudes below the lower flange. Coat all of the exposed machined
surfaces, including tapped holes and the access door flange faces with
Cosmoline No. 1058. Plug all of the tapped holes with tapered plugs. Cap
the pipe with a pipe thread protector.
JOURNAL HEAD AND TRUNNION SHAFT ASSEMBLY
(Storage Type C)
Store the assembly on timbers. Coat all of the exposed machined surfaces,
including tapped holes with Cosmoline No. 1058. Plug all of the tapped
holes with tapered plugs.
JOURNAL OPENING COVER ASSEMBLY (Storage Type C)
Store the assembly on timbers with the face which mates with the separator
body pointing down. Coat all of the exposed machined surfaces, including
access cover faces with Cosmoline No. 1058. Coat the exposed portions of
the hydraulic cylinder retaining studs with Cosmoline and cover them with
Web Sleeving.
SEPARATOR TOP ASSEMBLY (Storage Type E)
Place the assembly on timbers with the Separator Top Assembly/Separator
Body Assembly flange pointing down. Coat all of the exposed machined
surfaces, including tapped holes with Cosmoline No. 1058. Plug all of the
tapped holes with tapered plugs. Liberally apply a general purpose grease to
the linkage which is located on the top of the assembly. Grease the pivot
points of the Deflector Shaft Assemblies. Securely cover the assembly with a
heavy gauge clear plastic to prevent rain from washing the grease off of the
linkage.
PULVERIZER DISCHARGE VALVE/MULTIPLE PORT OUTLET
ASSEMBLY (Storage Type C)
Place the assembly on timbers with the multiple port outlet plate facing
down. Coat all of the exposed machined surfaces, including tapped holes,
with Cosmoline No. 1058. Plug all of the tapped holes with tapered plugs.
Securely cover the assembly with a clear heavy gauge plastic.
CAUTION
EXERCISE CARE WHEN HANDLING THIS ASSEMBLY.
ROUGH HANDLING CAN DAMAGE THE CERAMIC LINERS ON THE MULTIPORT OUTLET ASSEMBLY
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INNER CONE OR INNER CONE AND CERAMIC LINER SSEMBLY
(Storage Type E)
Place this assembly on timbers with the large diameter down. No other
preservation is required.
IF CERAMIC LINERS ARE INSTALLED, USE CARE IN
HANDLING TO PREVENT CRACKING LINERS.
JOURNAL SHAFT ASSEMBLY (Storage Type C)
Place the assembly vertically on timbers, stand on the base of the lower
journal housing. Check that each journal shaft assembly is completely filled
with the recommended oil. Check periodically for leakage at the oil seal. An
oil filled journal assembly is permanently protected.
At three-month intervals an oil sample should be taken from representative
journals, every 4th one. Run a 1/4 in. tube down the journal shaft until it
bottoms on the lower journals housing. Close the end of the tub to extract a
column of oil. If there is evidence of water, drain the oil and replace it with
new oil. If contamination is found in any one assembly, then all assemblies
should be inspected. After inspection, the journals should be refilled
completely and capped. At this time, all journal shafts should be turned one
revolution.
Before any pulverizer is placed into service, the excess oil must be removed
from the journals (siphon or pump) and the correct level established per the
Pulverizer Lubricating Specifications in the Pulverizer Operations section of
this Instruction Manual.
GEARBOX LUBRICATION UNIT, OIL COOLERS, GEAR BOX ACCESSORIES. OIL HEATERS (Storage Type C)
The lubrication system must be placed on timbers or pallets. Refer to
VENDOR'S MANUAL for detailed instructions.
SOLE PLATES AND MOUNTING PLATES (Storage Type C)
Place the sole plates on timbers. They may be stacked no more than six (6)
high. Coat the machined surfaces, including tapped and dowel' pin holes
with Cosmoline No. 1058. Plug the tapped and reamed dowel pin holes with
tapered plugs.
CAUTION
ENSURE THAT THE WEIGHT OF THE STACK DOES NOT CAUSE ANY OF THE PLATES TO BEND
2-6
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MISCELLANEOUS FASTENERS (Storage Type B)
Store these components on metal shelving. No other preservation is
required.
BOWL,BOWL HUB AND VANE WHEEL ASSEMBLY (Storage Type E)
This assembly is to be placed on timbers and oriented as if it was installed in
the pulverizer. Coat the exposed machined surfaces including tapped holes
and dowel pin holes with Cosmoline No. 1058. Plug the tapped holes with
tapered plugs.
Build a wooden crib over the top of the bowl and cover the assembly with
clear heavy gauge plastic. Secure the plastic so that it will not fall off or be
blown away by the wind. The crib should be constructed so that any rain
which falls on top of the plastic will drain off the side of the assembly and not
be caught in the bowl.
SEAL AIR SYSTEM PIPING (Storage Type C)
Stack components on timbers or pallets. Seal the ends of the piping, hoses
and fittings which make up the system with the appropriate type of plug or
cap.
CENTER FEED PIPE UPPER AND INVERTED CONE (Storage Type E)
Place the components on timbers. Coat the machined flanges with
Cosmoline No. 1058. Coat bolt holes with grease.
COUPLING ASSEMBLY (Storage Type C)
Store the coupling on metal shelving. Preserve per the vendor's require
ments.
LUBE OIL PIPING (Storage Type C)
Same as gear box lubrication system.
MOTOR COUPLING GUARD, BOWL HUB (CLEARANCE, AIR SEAL
AND GUARD. COAL SAMPLING FITINGS. THERMOWELLS. BULL
RING SHIMS (Storage Type C)
Store these components on metal shelving. No other preservation is required.
DIFFERENTIAL PRESSURE CONTROLLER (Storage Type B)
Store these components on metal shelving. No other preservation is required.
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BOWL HUB UPPER AND LOWER SKIRT ASSEMBLIES. SCRAPER
AND GUARD ASSEMBLIES. AND JOURNAL SKIRT ASSEMBLIES
(Storage Type C)
Store these components on metal shelving, timbers or pallets. Application of
general purpose grease to pivot point swill ensure rust protection, but it must
be washed off with solvent prior to pulverizer start-up. Coat the exposed
machined surfaces including the tapped holes with Cosmoline No. 1058.
Plug all tapped holes with tapered plugs.
WATER PIPING AND NOZZLE ASSEMBLIES (Storage Type C)
Store the components on pallets or metal shelves. Coat the exposed
machined surfaces including the tapped holes with Cosmoline No. 1058.
Plug all tapped holes with tapered plugs.
INNER CONE CERAMIC LINERS (Storage Type C)
When shipped separately, these components are to be stored on pallets or
metal shelving. No other preservation is required.
MOTORS (Storage Type B)
When supplied, motors should be stored on pallets or timbers and preserved
per vendor's specifications.
BOWL HUB HOISTING FIXTURES. JOURNAL TILT-OUT
COMPONENTS,GEARBOX ALIGNMENT FIXTURES (Storage Type C)
Store the components on pallets or metal shelves. Coat exposed machined
surfaces including any tapped holes with Cosmoline No. 1058. Plug all
tapped holes with tapered plugs.
COAL SAMPLING DEVICE. OIL DIP STICK. SPECIAL TOOLS (Storage
Type B)
Store these components on metal shelving. Coat the exposed machined
surfaces including tapped holes with Cosmoline No. 1058. Plug and cap all
of the holes and ends of fittings with tapered caps
2-8
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TABLE OF CONTENTS
INSTALLATION PROCEDURES
PART 3
TITLE
PAGE NO.
INTRODUCTION ..................................................................................... .............
PULVERIZER COMPONENTS......................................................... .....................
SUB-ASSEMBLI ES ....................................................................................
LOOSE PARTS ...........................................................................................
TOOLS ........................................................................................................
GENERAL ASSEMBLY .......................................................................................
SOLE PLATE AND MOUNTING PLATE ALIGNMENT AND GROUTING ..........
Pulverizer ........................................................................................................
Motor ...............................................................................................................
MILLSIDE AND LINER ASSEMBLY ...................................................................
BOWL, BOWL HUB AND VANE WHEEL ASSEMBLY ....................................
SEPARATOR BODY ..........................................................................................
SEPARATOR TOP ASSEMBLY ........................................................................
MILL DISCHARGE VALVES AND MULTIPLE PORT OUTLET ASSEMBLY ..
OUTLET VENTURI AND VANES ASSEMBLY ................................................
INNER CONE WITH LINERS .............................................................................
JOURNAL OPENING COVER WITH SPRING ..................................................
GEARBOX ASSEMBLY INSTALLATION .........................................................
BOWL HUB SKIRTS AND INNER AIR SEAL INSTALLATION ........................
SECURING THE GEARBOX .............................................................................
CLEARANCE AIR SEAL ...................................................................................
PULVERIZER MOTOR .......................................................................................
JOURNAL INSTALLATION ...............................................................................
Journal Assembly Installation ....................................................................
Journal Head Assembly Installation ..........................................................
Journal Roll And Shaft Assembly Installation ..........................................
TRUNNION SHAFT, JOURNAL SPRING SEAL AIR ........................................
FEED AND FUEL PIPING ASSEMBLY .............................................................
DISCHARGE VALVE LIMIT SWITCH SET-UP .................................................
CONTROLS .......................................................................................................
FINAL ADJUSTMENTS, JOURNAL SPRING PRELOADING PROCEDURE,
JOURNAL ROLL-RING CLEARANCE, JOURNALSPRING POSITION ......
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PART 3 - INSTALLATION
PROCEDURES
INTRODUCTION
The pulverizer described in this manual is too large to be shipped assembled.
These installation instructions provide a sequence for assembling the normal
subassemblies. Special site conditions may allow for more or less
subassembly of components. All required fasteners, sealants and lubricants
are shipped loose.
TO PREVENT POSSIBLE EQUIPMENT FAILURES,ENSURE THAT THE CORRECT BOLTS LENGTH AND
GRADE ARE USED IN PROPER LOCATIONS DURING THE
ASSEMBLY PROCEDURES. TORQUE ALL FASTENERS TO
THE VALUES INDICATED IN TEXT, ON DRAWINGS OR ON
DRAWING B-GP-2175 LOCATED WITH THE TOOL
DRAWINGS
Pulverizers are frequently assembled in place early in the erection sequence,
sometimes prior to the erection of the building steel. It is recommended that
gearboxes, lubrication systems, journals and all control be retained in
storage and be installed on the pulverizers just prior to [not more than six (6)
months before] unit commissioning.
PULVERIZER COMPONENTS
SUBASSEMBLIES
The normal subassemblies are:
1. Millside, liner and seal air header assembly.
2. Bowl, bowl hub and vane wheel assembly,
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3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
Separator body assembly.
Inner cone and spout segment assembly.
Outlet venturi and vanes assembly.
Separator top assembly.
Journal head and trunnion shaft assembly.
Journal shaft assembly.
Journal opening cover assembly,
Gearbox assembly.
Gearbox lubrication system.
Mill discharge valve and multiple port outlet assembly.
MAJOR PULVERIZER COMPONENTS ARE KEYED OR MATCH
MARKED TO ENSURE PROPER ORIENTATION OF THE AIR
INLET, JOURNAL OPENINGS AND FUEL PIPES. EACH COMPONENT lS IDENTIFIERED WITH A SERIAL NUMBER TAG. USE
CARE TO INSTALLTHE CORRECT SERIAL NUMBERED PULVERIZER AND ITS COMPONENTS AT THE LOCATION INDICATED ON THE CONTRACT DRAWINGS.
LOOSE PARTS
The following items may be bundled Or boxed and are normally shipped
unassembled:
13. Clearance Air Seal and guard components.
14. Inner cone support pipes,
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ABB CE TYPE HP943 PULVERIZER -INSTALLATION
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15.
16.
17.
18.
19.
20.
21.
22.
Center feed pipe- upper.
Center feed pipe -lower.
Seal air piping.
Discharge valve air header and piping
Seal air header valves.
Motor coupling.
Motor coupling guard.
Sole plates and mounting plates.
TOOLS
23.
24.
25.
26.
27.
28.
29.
30.
Coal sampling device.
Bowl hub hoisting tools
Gearbox alignment tools.
Gearbox removal rail kit.
Hydraulic stud tensioner (bowl/gearbox),
Journal tilt-out components.
Journal spring preload procedure.
Oil dipstick (for journals).
As components are brought to the site for assembly their mating machined surfaces
must be cleaned and a light film of oil should be applied. Unless instructed otherwise,
bolts and nuts, cap screws, and studs should be lubricated and tightened securely
per B-GP-2175 (Refer to tool drawings),
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ABB CE TYPE HP943 PULVERIZER -INSTALLATION
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those fasteners which must meet special tightening requirements are identified on the engineering drawings and in the text.
TORQUE VALUES SPECIFIED ON ENGINEERING DRAWINGS
AND IN THE TEXT SHOULD NOT BE EXCEEDED.
THE APPLICATION OF RIGGING IS THE RESPONSIBILITY OF THE
USER. CARE MUST BE USED WHEN HANDLING COMPONENTS
TO PREVENT INJURY TO PERSONNEL OR DAMAGE TO EQUIPMENT. LIFTING EQUIPMENT, CRANES, CHAIN FALLS, COME
ALONGS, CHAIN AND WIRE ROPE SLINGS, ETC. MUST BE ADEQUATELY SIZED TO SUPPORT THE LOADS BEING LIFTED.
Drawings dealing with the following equipment and procedures are
included with the Tool Drawings. Tools to perform these procedures
may not be supplied.
1. Gear Box Removal Rail Arrangement.
2. Journal Bearing End Play Arrangement.
3. Journal Grinding Roll Removal Application.
4. Sole Plate Stud Tensioning.
GENERAL ASSEMBLY
The installation sequence assumes a normal stack up of the
preassembled pulverizer components on a prepared foundation.
Detailed assembly recommendations follow this General Assembly.
MAJOR PULVERIZER COMPONENTS ARE KEYED TO ENSURE
PROPER ORIENTATION OF THE AIR INLET, JOURNAL OPENINGS
AND FUEL PIPES. EACH MAJOR COMPONENT HAS A TAG WITH
THE PULVERIZER SERIAL NUMBER. USE CARE TO ENSURE
THAT THE CORRECT SERIAL NUMBERED PULVERIZER AND ITS
COMPONENTS ARE INSTALLED AT THE LOCATION INDICATED ON THE CONTRACT DRAWING K6100.00 .
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ABB CE TYPE HP943 PULVERIZER -INSTALLATION
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It is presumed that major pulverizer components will be "stacked up" and
protected while the balance of the plant is erected around them. Then four
(4) to six (6) months before unit start-up, just prior to unit/equipment
commissioning, the remaining components will be installed.
1.
Install and grout the gearbox sole plates and millside mounting plates.
2.
Install millside and seal air header assembly.
3.
Place bowl hub upper and lower skirt and scraper and guard
assemblies in the millside (DO NOT remove preservative coatings).
4.
Build up cribbing from the sole plate and place bowl, bowl hub and
vane wheel assembly inside the millside.
5.
Install the separator body assembly.
NOTE
Inner cone liners may be installed on the inner cone before it is
placed in the separator body. If this is done use care in
handling the inner cone and liner assembly to prevent breakage
of the liners.
6.
Place the inner cone (and liners) inside the separator body.
7.
Slide the inverted cone up the center feed pipe of the outlet venturi
and vane assembly. Secure the cone temporarily with the set screws.
8.
Place the inverted cone and outlet venturi and vane assembly inside
the inner cone.
9.
Install the separator top assembly.
10. Assemble the mill discharge valves and multi port outlet plate to the
separator top
11. Assemble the outlet venturi and vane assembly to the multiple port
outlet plate.
12. Assemble the inner cone to the classifier drum.
13. Install the center feed pipe (upper).
14. Temporarily install the journal opening cover assemblies.
15. Close and secure the millside and separator body doors
16. Seal all remaining openings with waterproof covering
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ABB CE TYPE HP943 PULVERIZER -INSTALLATION
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The balance of the erection procedure will be delayed until about six months
prior to unit commissioning.
17. Remove the journal opening cover assemblies.
18. Lift the bowl, bowl hub and vane wheel assembly and remove cribbing.
19. Install the gearbox.
20. Assemble bowl hub to gearbox, install bowl hub skirts and scraper and
guard assemblies.
21. Align components, set air seal clearances.
22. Secure and dowel gearbox.
23. Install journal heads and trunnion shafts.
24. Install journal shaft assemblies with rolls.
25. Tilt-in journal assemblies.
26. Install journal cover assemblies.
27. Set/check spring compression.
28. Install gearbox lubrication system.
29. Install pulverizer motor, check rotation, assemble coupling.
30. Install instrumentation and controls equipment.
31. Set roll-ring and spring to journal head clearances.
32. Check all equipment, close pulverizer and energize for operation.
SOLE PLATE AND
MOUNTING PLATE
ALIGNMENT AND GROUTING
Pulverizer
NOTE
The following steps refer to Drawings K6100.00 unless
other Stated.
NOTE
For recommendations concerning the grouting of sole
plates,see ABB CE Design Standard 27-68(index 6.26)
1. Prepare the foundation for grouting per Design Standard 27-68
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