I. Book

TRKIYE ELEKTRK KURUMU CATALAGZ! THERMAL ' POVVER PLANT

UNIT N o . 2 , INSTRUCTION MANUAL

M / S TRANSELEKTRO V. MNNICH FERENC UTA 13 '

"H"-'1394 BUDAPE5T HUNGARY

C o n t r a c t No.: 1 2 2 - 4 6 - 6 / 0 5 6 6 I. Book

C 0 N T E N T 5

I. BOOK 1./ OPERATHG TIAUUEL POR THE STEAM GMERATING UITIT

l.l* Specification of the plant 1.2. Starting of the steam generator from cold

state 1.3. Starting from marm state 1.4. Operation 1.5. Putting the boiler out of operation 1.6. Drawings

2./ RA.PH /REGMERATIV AIR PREHEATER/ 2.1. Mounting instrution of RAPH 2.1.1. List of mounting designs 2.1.2. General Information 2.1.3. Order of mounting 2.1.4 Sketches of order mounting 2.2. Operating and maintenance Instructions 2.2.1. Operating instructions 2.2.2. Maintenance instructions 2.2.3. Operating and maintenance plans and drawings

3./ EVT - Beater iffleel Mili Type; s 32.60. 3.1. Operation 3.2. Maintenance 3.3. Repair 3.4. Drawings list

4./ PLVIS shaft clutch Model W 750 4.1. Operating instruction 4.2. Instructipn Leaflet concering the Alignment 4.3. Supplement to the Operating instructions W0 4.4. instructions for the Disassembly and Reassembly

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5./ PEEDER

6./ Blt conveyor - with scraper chain

II. BOOK 7./ OIL BIMERS

7.1. Instruction manual for oil burners type ENO-1500 M and control eq;uipnett MO-SOOO M

7.2. Oil bumers type MO-1500 M G-354-00 7.3. Mainte-nance Instructions for valves type PSZN 7.4. Instrumeut manual for flame relay 5180-0 developed by TKI 7.5. Hardware Bescription 7.6. The PA-8K LOKATOR 7.7. Instrument manual for the control appliance V-Y 3041

8./ SOOT - BLOWERS 8.1. Water Blower: Type SK 58 E 8.1.1. Description of the Blower 8.1.2. Transport and Installation 8.1.3. Start - up 8.1.4. Operation 8.1.5. Routine service 8.1.6. General maintenance 8.1.7. Sketches

8.2. Long retractable blower Type: RKS 80 E 8.2.1. Description of the blover 8.2.2. Installation and start - up 8.2.3. Operation 8.2.4. Maintenance repair and clear avray of faults

9./ PAN 9.1. i d fan 9.1.1. Operating conditions

I '

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9.1.2. Description of the fan 9.1.3. Service instructions 9.1.4. Mai-ntenance of the fan

JF *

9.1.5. Lubricatin, iTistructioas 9.1.6. Causes of trubles and repalr 9.1*7. Demounting and mountiag of axial fan parts 9.1.8. Spare parts list 9.1.9. Connecting-up of the piping 9.1.10. Conservation for Compressors and Pans

K-COK 9.2./ FD - fan

9.2.1. Operating conditions 9.2.2. Pan description 9.2.3. Aerodynamic prepequ. 9.2.4. Maintenance of the fan 9.2.5. Lube oil instructions 9.2.6. Causes of troubles and repair 9.2.7. Dismounting and mounting of fan parts 9.2.8. Spare parts list. 9.2.9. Connecting-up of the piping 9.2.10. Conservation measures

9.3./ KNV-63/2880 centrifugal fan

9.3.1. Data sheet 9.3.2. Installation

9.4./ VHK-160/167-960 9.4.1. Data 9.4.2. Placing 9.4.3. Guarantee 9.4.4. Storage 9.4.5. Mounting 9.4.6. Servicing 9.4.7. Handling 9.4.8. Maintenance 9.4.9. Spare parts 9.4.10. Appendix

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9.5. TIK-45/14440 Bearing - coollnr fans 9.5.1. Data Sheet ^.5.2. Installation n.5.3. Guarantee 0.5.4. Storage 9.5.5. Assembling 9.5.6. Putting the "^ an into "'nerfition 9.5.7. Maintenance 0.5.8. Spare porst 9.5.9. Enclosure to SERVCE UmjAL

10. .UTGT ELTCTRICAL PRECPITATOR 10.1. Descriptoin and Operption Instructions 10.1.1. General Information 10.1.2. Technical Data 10.1.3. Mode of Operation ""0.1.4. Structural Design I,0.1.5. Operating Instructio s 10.1.6. Uaintenp.nce 10.1.7. Installatlon and Rem'val Instructions 10.1.8. Walkthrough Inspecticn of ESP 10.2. Instruction for Stor?^e and Erection 10.3. Controls for HT - Un? t s T)010/D011 10.4. Control cabinet for ?ux. drives 10.5. RICO High voltage

Direct current equT'Tient 10.5.1. linit parts 10.5.2. Punctioning 10.5.3. Instructions for storage 10.5.4. Instructions for Tnai-> tenance 10.5.5. High vottage control unit Type TH-S 5 10.5.6. H.Y - unit testing

11. MOTOR II.1. Type PBDO 716 SlO 11.1.1. Introduction 11.1.2* Tecljnical data 11.1.3. Technical description 11.1.4. Stator ^

.IV.BOOK

y

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11.1.5. Rotor 11.1.6. Beariags 11.1.7. Ventilation 11.1.a. Handlig ad malntenance instnctions 11.1.9. DravTings of doctmentation

11.2. Type: FBDO 566 S4 11.2.1. Introduction 11.2.2. Technical data 11.2.3. Technical deseription 11.2.4.. Stator 11.2.5. Hotor 11.2.6. Bearings 11.2.7. Ventilatlon 11.2.8. Handllng and tnalntenatce instruction 11.2.9. DrauTngs of dolcumentatlon

11.3. Type : PBDO 566 L6

11.3.1. Introduction 11.3.2. Technical data 11.3.3. Technlcal description 11.3*4. Stator 11.3.5. Rotor 11.3.6. Bearings 11.3.7. Ventlation 11.3.8. Handling and malntenance instruction 11.3.9. Drawlngs of dokumentations

11.4. EVIG / Threo phases inductlon motors/ 11.4.1. Packing 11.4.2. Voltage 11.4.3. Momtlng of the motors 11.4.4. Mounting of the "bearings 11.4.5. Shaft end 11.4.6. Temperature rise 11.4.7. Protection 11.4.8. Start - delta swlch 11.4.9. Motor with wond rotors

6

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11.4.10, Rotor started 11.4.11- Spare parts 11.4.12. Repair 11.4.13- Connection to the raain and

first startlng

12. Operating Instruotions for Vertical Centrifugal Pumps / ALI\7EILR /

13. ATBIA - Actuators 13-1- Special features 132- Practical considerations 13-3. Anma - compact 13-4. Basic nuipment 13 - 5. Sizing data 13-6. Dlmensions 13-7. Type GST 12-1600

14. BEMARD - Actuators 14-1- General 14-2. Electric Actuators 14.3. Reduction (earboxe3

15- SfflPSU, Safety Relief Valve Type : VS 99

15-1- Disassembly 15-2. Inspection and servicing 15-3. Assembly 15-4- Inspections after start - up 15.5. Spare parts 15-6. Drawings

16. Solenoid Control Valves 16.1. Deseription 16.2. Design 16.3- Mode of operation 16.4- Installation

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17

16.5. Insulation 16.6. Diassembly 16.7. Inspection and Servicing 16.8. Assembly 16.9. Piping 16.10. Spare Parts 16.11. Drawings Slag - removing 17.1. Technical Description 17.2. Siting and Mounting 17.3. Lubrication 17.4. Coramissioning 17.5. Operation and Maintenance 17.6. Conditions of Guarantee 17.7. Technical Data

18^ Hydraulics of Submerged Gate /HYDROPNEU/ le.l. Descriptlot

Lines and connections 18.3* Puttlng iTito operation 18.4. Maiutenance 18.5. A.pparatus llst

19- Slag Crusher Rolling llll TYpe: HPJ 80/120 19-1. Scope of application and oporation 19*2. Technical description 19.3. Technical data 19*4. Poundation and assembly instructions 19-5 Asseily and maintonance 19.6. Safety instructions 19.7. List of apare parts

20. Installation - and Operation instructions for Globe Valve 20.1. General 20.2. Putting Into service and operation

20.

20.4.

20.5.

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Maintetance Repacking - and replacing the gland packing Disman-tlitg and repair

21. nstallatlon, Treatment and Operation of Pressre measring Instruments.

23.

21.1. 21.2. 21.3.

Installlng treatment Operation

22. Conveyor Belt CB 7A/B; CB 9A/B and CBIO 22 .1. 22.1.1.

1.2. 1.3. 1.4. 1.5. 1.6. 1.7. 1.8. 1.9. 1.10. 1.11.

1.12. 1.13. DEHOPLAST 23.1.

Blaulpment manual Prellminarieg Technical Specifications Teohnical Descriptlon Manufacturlng Instructlons Transporting Assembling Patting Into Operation Operation Uaintenance Safety Instructions Techn. Dese. for Pire Protecting Spare Parts List Appendices

Problems conceming the storage and conveyan^se of bulk. materials

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23.2. Details of lining 23.3. Non - adhesiou and sliding

properties 23-4. Abraison 23.5. Ezamples of lining

.ti";..:-/;'.';.- y.

l i

.r-

EVT Energie untJ Verfahrenstpchnik GmbH - Stuttgart

Preliminary Operatlon Manual

T" " - - - <

for

Natura!^ Circulation Steam Gener&tors

with EVT Engineering

Stuttgart, 31.06.80, Dept, IS-Mer/Ea

Plant: CatalagziAurkey Order No: 5,36 52o

t - 1 .

I N D S X

Page Prefsce 4 1. Gpecificatlon of the plont 5 1.1 ^peificstion of the steom generotcsr 5 1.2 Cepact^ data 7 1.3 fi8X. perm33ble water and ateam

temperatares 8 1.4 Suppl^ water and boiler water values 9 1.5 3afety equipment 10 1.51 IIP feduction station 10 1.52 D m m safety valves 10 1.55 liP aafety valvee 10 1.54 Reheater aafety valves 10 1.6 Parnace air 11 1.7 'irirg 11 1.71 Ignition firing 11 1.72 Coal firing 11 1.721 Firing dota ' 12 1.722 Feeder 13 1.723 Deslagger 13 1.724 31afi cruaher 13 1.8 Flue ges 13 1.9 Deashing 14 1.91 J5VT deelagger 14 1.92 Diving plates 15

BMZ82 F N Y V II .

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Page

2. Adjustment data 15

3. I^srting of the steam generator rtom eoid .8|;ete 15

3.1 -Pr^p^i^tione 15 3,11 Pr^paratoi7 work /general/ 15 3.12 PFeparatons at the water/stQ8m aide 17 3.13 Flling of the boiler 17 3.14 Preparation fet Lhe air/flue gss side 18 3.15 Ignition oLl firing 19

"" 3.16 Coa 20 3.17 Delaggex 20 3.18 Mills 20 3.2 Putting into oeration 20 3.21 Au*iliai7 agfiregotes 20 3.22 Pre-ventilation 21 3.23 Ignition of oil-firing 22 3.24 Acceleration of ihe steam generator 22 3.3 Putting into'operotion of milis 25

4. 3terting from warm state 26 . 4.1 Hot-starting 26 4.2 WanQ^starting -

*

27

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S042U F N Y V 11.

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Pge

5. Operation 28 5.1 Operption of the boller ^ 28 5.2 Fii?ing ' , 29 5.3 E^utting a mili out of operation 30 5.4 Wet'dea3hing 31 5.5 Gafety cut-out system 31

6. Putting thg boile^r out of operation 32 6.1 Stoppinfi for normal atandstilla 32 6.2 Stoppdng, cold-running and dischorging 33

7. Generol principlea for boller operation

Annexes; Jtorting diagrom - cold-storting Strting diagram - orm-storting 2 diagrana of permisslble temperature change velocities.

I>A B04232 F N Y V 11.

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Preface With regard to the operation and maintenance of the plant described hereunder we suppoae that the persons entrusted with such tasks are properl^ slclld Therefore we can forbear to explain details generslly known| the more aa an operation manual cennet reploce ali necessary'experience and knowledge as a whole,

A

In principle the legal regulationa, n particular "Technische fegeln fr Dampfkeasel" TRD 601, /technical rules for steam generotora/ "Sicherheitstechniache Richt-linien" /technical direction for the safe operoting/ and the general lahour aafety regulationa are to be ob-aerved*

This operation manuol is written to give directives for operation under the a.m. auppoaitionp The boiler ia to be operated and mointained according to thia nonual,

Th practcal advisea of e^cperteea delegated to the si-te by.different deliverers, further the detail-operation mauals edited by the sub-auppliers ere always volid and very important aa well.

804252 F N Y V 11.

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1. Specification of thg plsnt ^ 1.1 Gpecificotion of the steam gencretor

/3ee 3oiler Circuit Diagrem No, 5 520/012-005/202/

The ateam generator is designed for nstural circu-lation and simple-ateam reheoting. ^ t ia a single-pass conatruction with a secnnda^ idling pass, The outer wal3 of the steam generator ere formed bj' boiler tubea tight welded together, wich ere fed with water by collectors of regiater type The whole steam generator is auspended et the top of the steel atructure and can xpond downward without limit, Through the economiser the feed water gets into the drum to fiil the up- and downcower tubes /furnacc chamber/ of the system. By heating the furnoce cham-ber a weight difference occurs between the water in the downcomer tubca and the water/a tcam mi*ture in the heated upcoaer tabea, wich resulta in a natural circulation, '

In the drum the water and steam are separated* Together with recharged ter the seporated water ia fed into the boiler tubes again, while the ge-ne rot ed steam flowa through the succeaaive IIV-su-perheaters* The suapending tubaioprheater No*l

0

is constructed with threo bronchos the auccesaive lP-superheaters No. 2-4 with two branches. To compensate ineqU8ity of heat extension in the furnece chamber caused by different mili combina-tion, the individual superheoter branches are crosoedy each tiine to occupy other poations in the flue gas flow.

/t 8tM2a2 F N Y V 11.

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Oetween the superhe&tcrs No 2 and ^ and 4 each branch contoins injection coolers for re-gulation f the steom temperature, After the fi-nal superhester /No. 4/ the two branches ere u-nited. ^rom the re the ateam flow3 to tl iIP part of the trbine or -et atarting or at break-down8 - it ia guided through a IIP reduction stotibn to the cold rail of the reheater. The steam coming from the HP trbine or re^acti-on station flows through the rebeotcra la, Ib and 2 also divided into two brancheg. etween the reheaters. Ib ond 2 each branch inciudea in-jection coolers, The reheated steam is then gui-ded to the medium-pressure part of the trbine or - at starting or ot breakdowna - through the low-pro3sre by-pess to the condenaer.

804252 F N Y V 11.

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1.2 CaPBCty deta

lP ateam generating capecity t A 480 ^ermissible pressure bar 170 Druffl pressure b ^ 154,65 Live-steam temperature 538 Pressure at superheater outlet bar 136,4 Feew8ter temperature 250 Heheatcr 3teomquantity t/h 404 Pressure at reheater inlet bar 39,93 Steam temperature at reheater

inlet 369

Pressure at' reheater outlet bar 38 3teem temperature at reheater outlet 538 Air temperature after the steam air preheater 20 Air temperature before rotating ir preheater 40 Air temperoture"after rota-ting air preheater 334 Flue gas temperature 158

8M2S2 F N Y V I I .

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^ximmD permiasible stesm teinpereturea

Superheater outlet No,t)l 392 Superheeter outlet No.OlI 474 Superheeter inlet No.OlII % 442 Guperheeter outlet No.III C 512 Superhester inlet No.OlV 495 Superheater outlet No.OlV C 541 Reheeter inlet No.ZI C 4^6 Heheoter outlet No.ZI ,C 548 Reheater inlet N.ZII 491 iieheater outlet No.ZII 54^

804232 FMYV 11.

1.4

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FeedtfBter dato /at continuous operotlon, measured at the steam generator inlet/

General requiremeit: Conductivity: /observe authoratative values for boller water, see below/

pH-value et 25C, with volatile alkalizer only

clear and colourless

Oxygen /Oj/: Total iron /Fe/: Total'copper /Cu/:

i

Total carbonic acid /CO^/ Ilardness: KMnO^ consumption: Oil:

3oiler woter values /at continuous operation/ Conductivity: /at 25 C in the by-pass on the spot, samples being taken continuously/

Silide acid /3O^/ pH value at 25C: p value

>9

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1.5 SaTcty eguipment

1.51 IIP rcduction station To protect the reheeter at storting and possible breokdowns of the tarbine, the IIP steam is giu-ded through two IIP re^iaction stations to the re-heater and through the LP reduction station to the condenaer.

The IIP reduction station alao aerves as sefety valve.

3y injectioa the steam temperatures are cooled af ter the IIP reduction stations to the. reheater inlet temperatures.

1.52 ^rum safety valve At broakdowna resulting on inodtniaible presaure increasG in the evaporating part of the boilor it ia protpcted by a safety valve desifined for 50% steam capacity.

1.53 IIP aafetv yalve The HP part of the boiler is protected by a safety valve at the final overheater outlet, designed for 50% steam capacity.

lm3A Reheater safety valves 2 safety valves at the outlet serve for protec-tion of the reheater part.

804232 F N Y V 11.

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1.6 Fumoce 9r

j-he air arvi flue gas passea ere constructed with two passes, Two fresh-oir sx8 ventilators with impeller blede regulstion supply farns'ce oir through the steam and the rotating flue gea air-preheoters to the burncrs^ The tv/o rotating pre-heoters are regenerative onea with rototing heat storing parts. At rotation through the gos chonnel the hejting L'lementa extract heat from the_ flue gos, tronsmitting it to the furnace air during rotation through the air channel, 3y the steam preheater installed before each fresh-air venti-lator the furnace air can be warmed up to +20 Recirculotion of hot air enableo further heating to + 4 0 a ^ per.nonent maxiaum load,

1.7 Firnn ^

1.71 Inniton fping a burners of abt. 30^ total heating capacity, arranged in equal prportion at both side walla. Fuel: heavy: oil of 9600 kcal/kg /40,2 UJ/kf/.

1*72 Coal firina /See Draving No. 36 520/0*54-001/0018/ The main firing sistem consists of EVT type stone coal heatiqg with direct dust injection, ' inciuding: ;

6 coal milis of 3 32.60 type, cpmbined recirculation ductg and chutea,, box-tj'pe dassifiers and dust ducts from the milis to the burners.

S04232 F N Y V IL

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From the pit coal bunkcr the cool 3 supplied to the mili ver distributoro of atagelessly adjustsble speed, a coal chute ond follwa^. In the mili it is dried by odding hot flue goses ond then ground, By odding hot^ir and . cold gog the fuel temperoture of obt. 130C

3 odjusted nfter the closaifier /claasifier temperoture/. From the mili the cool dust/gna mixture 3 blown through the closifier, cool dust ducta and burncr into the furnace cham-ber. In the classifier the rough and fine porticles are separated from each other, The big parto are returned to the grinding pro-ccss. The furaoc'e air is guided to the bur-ners trough upper, central, lower and com-buation air ducts; the cotnbustion air alao oervoa fr cooling the burner caaing.

1.721 Firinn da ta

Type of fiiring: tangentiol firing ^alculated: 100% boiler capacity

29,66 kg/a Turkiah mineral carbon

No. of milis: 6., ene of them as reaerve,vr-n'. i^ f^ s^ .^ O

Max. milling capacity per mili:8,14 Vg/a Type of clasifier: box-type claasifier Tempereture after classifier: 130 C Origin of fuel: Coal-mine, atalagzi

304252 F N V V II .

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304232 F I4YV 11.

Gorotee fuel

Lower heating vslue: 12.435 MJAg Ilumidity: 18% Ash: 40% . Volotile conponents:

1.722 Pisiribtora

Not inciuded in the delivery scope of EVT,

1*723 Desla/^ r.er

Type: 1400x19170 Number: 1

1.724 31a/^ crugher t

Type: NFJ 80/120 Mumber: 1

1.8 r-

For removal of flue gos two ID fans ere at dis-posal. From the boil/er outlet to the funnel the flue gases pass the ownward-leading flue gaa duct, the rotating air preheatersi and the pre-cipitatora. At the end of the furnace chamber part of the flue gaaea is sucked off by EVT coal milli for drying the coal and as carrying gaa., Another part of the flue gases is sucked off of ter the electric fil-ters b;> two fnns. liost of this cold gas quantity is used for.regulotion of the mili outlet tempe-roture. At not full lond operntion the cpld gas portion tnk^s part in Lhe reheater temperature regulation. '

i

I v

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1.9 ^eashin^

1.91 EVT deosher /Drawing No. 5. 520/670-002/0e/

' i'he ashes profluced in the furnsce chomber and on the coupled after-heoting surfoces ore ex-tinguished in the wet desiseler and transpor-ted to the outlet by scraping blades guided b;y t;vo endless chains. I''or 3ow cooling of big pieces of slag ond prevention of posaible eyplosions occuring ot sabmerging of the slog e floating platform is built in. The deslucpr is filled up to the overflow, the wnter cupply is regulated hy a thermoste-ticall^ - controlled reglatr valve, to keup the WDter tempernturo ot about 60C. From the deslai'^ .^er the aah ia thrown through crushers to a coupled conve;yor belt trans-porting it into the v;et aah bunker, The discharge specd of the deslog;;er ia adjua-table in.2 stagea. In case 6f a repir of the deslagaer becoming necesaary in the courae of operation the boiler is to be sealed temporaril^ by cloaing of the diving platea.

4

604293 FNYV t.

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1.92 Divinr-, plotcs ^ he cliving plates ensure oirtight aesling bet-\veen the furnace chomber and deslogi^er. They corujiot of one front, one reer and aeveral . right- and left-hond uide plates actiated hydraulically. At breakdovma of the deslafi-ger the boiler can be sealed by closing the diving plates, so thot the necessor^' repairs or reploceiiient of the deslag^^cr can be exfffu-ted. Prior to closing the diving plates it is advi-asbie to reluce the boiler output to minimum coal consumption- Dcpending on the quantit;y of ashes, this state of operation can be nain-tained for ::bt. 3 hours.

2. I^ckinA and stoppin;^ criteria /3ee ^ VT locking plons/ ^rBWng No 5 0 5 520/021-01/'52

5.36 520/021-08/32

3, otortig^T of the steam r.enerator from cold state

3,1 Preparationa

3,11 ^reparatory work /general/

Ali inspection and man holes in the boiler and at the flue gas and air channels are to be closed. The safety valves and reduction atati-ons must be ready for operation. The deslagr^er is to be filled with water, Ali aggregates of the block plont must be put in a state reody for operation, as the following parts of the boiler, specialy:

8M2M F N Y V 11.

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Feedvveter pumps FD fans id fons Cold gas fans Air prehesters Precipi tators Mills D3tributors Desla^y^er 31og crusher i^ lue dst deasher Ignition firing Soot blower

The following operation must be at disposal in sufficient quantitie3: Feedv/ater

Pit cool Oil Compre33ed air Coolini^ yyater Flshin;^ WBter I/tnition f^ aa Steem

occording to VGB /germon/ regula-tions or to the contrect, res-pectivel^ in the bunkers ver distributors for starting at ali necessary placea for ali aggregates for deslagger for ignition of oil barners for oil preheoting and carborotion

804202 F^^^v .

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3.12 Preporotioru3 at the ?;oter anc3 steam aide

If the boller is ompt^, the boiler fittings are odjuated reop, their odjustmont is checked be-fore filling. Open the bleoding volv^ of the econoraiser and drunu Close outlets of econoaai-ser and evaporator, Open outlets: 3aperheeter 1 to superheater IV, reheater I, reheate.r II. Open all locking elementa to measaring ond control devices. Open hand-operoted shut-on valves in injection pipes: 2 X injcction 1 :to superheater II 2 X injection 2 to superheater III 2 X injection to reheater I Open rni' '.le presGure tap at the feedwoter pump /for reteater injection/. i:^ ke the emer/ency outlet of the drum reod^ for operation. Adjust the IIP rc^uction atatlon to abt. 50:6.

3.13 Filling of tho boiler By means an electric feedwater pump the boiler is filled throuch the by-pass feedweter valve with o water quantity of 100-150 t/h. During the filling close the bleoding valves of the economiser, when water appears steadil^ at that place. Filling is finished ss soon as the lowest v/ater level is re-ached n the drum*

lefillinA of the boiler If the boiler '//as shut down in normal operation \vlthout eaptying it, all water-Gde bleedings remaiR closed, Also refilling takcs place to the lawest v;ater level in the drum.

804252 FITVV 11.

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Preporptions ot the oir and flue fies sitle nefore the ID fons, FD fans and cold gas fsns are switched on /see the menufacturer's direc-tions for operation/ the dompera prnvided ot . the flue gas and air side ere adjustt^ as fllows: 1, In-ernal and/or externel air suction to be ope-

ned /adapted to temperature conditions/ 2. Air iampers before FD fan to be opened, bchind

fan to be closed. Dampers behind the fon get a starting impulse, when being switched on, Air dampers before oir preheater to be put in throttie position, after air preheater to be opened. Dampers in cold air bj-poso duct /air prehea-ter/ to be opened

5./3econdory oir regulating dompera to be opened, secondary air and oil air valves to be put in cooling position,

u. Ilopper air regulating damper to be put in coo-ling position, hopper air valves to be opened.

7. Mili hot-air, mili cold-air and mili locking-air dampers to be closed.

8. lot-air recirculation dampers to be closed.

9- Flue gaa dampers before air preheater to be opened.

BM2S2 FNVV U .

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10 Flue gos dampers before ID fan ond in connection cuc t to be openerl.

11. flue g8S dempera af ter ID fan to be closGd. When the fan starts they get order to "pen". ^

12. Put dampers before cold gos fen ond in ita connection duct in "pen" position.

13. The dompers ofter the cold gas fans get order to "pen", when the fans a-re strted. Cold go3 dampers before flue gas recir-calstion duct to be put in about 10% "open position".

3houl:l it become necesory for any reason to operoLe only the fans installed ot one side or in other crosG combinations, the dampers are to be adjasted nccording to the air and flue gos duct reqaired for this. /Circuit Diagram 5 . 36 5 r o / 0 3 4 - 0 0 1 / 0 0 1 d / . The two ateom air prehtioters are put into ope-ration ahortly before starting with the FD fans according to the aupplier'a direction for operation.

3 . 1 5 Ignition oil firinR This port of the plont is to be put into opera-tion and prepared according to the supplier'a directions for operation The oil heatitg is read^ for ignition a: aoon as the locking con-ditions are met and the boller ventlation is reolizcd.

a(H232 F I ^ V 11.

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3.16 Coal The coal bunkera must be filled eni the coel in the feeders must be advanced to the output end ^ate vole in riust duct to be closed. Gate velve before mili door to be opened,

r-

3.17 )e3a;>r.er /3ee pecial Directions for Operation/ The dislascer must be filled to the overflow. The flushing wotQr necessg^ for the return pulle^/s .in the through and the choin-cleaning a^stem before the delivery end is to be turned on. The diving plates must be opened as to dive into the water of the deslagger,

3.18 Coal milis Mills are to be carefully controlled in point of view of readiness for operotion, occor-lin/; to their Gpeci-al Directions for Operation. Gpecial core ahould be taken that the cooling ^ v.jter is odjusted correctl;/ and the oil levels reach the mid'le of the oil level gaagea. Check working poaition.of clasaifier's dampers.

3.2 Putting into operation

3.21 Auyiliary ag/^regates The Buyiliary ag^'^egates can be put into operation simultaneously with filling the boiler. For ali oarts of the plants the 3peciel Directiona for Operation are to be observed. Putting into operation takes place according to the following sequence:

804292 F N Y V 11.

- 21 -

1. Jteam preheoters ^ 2. totating air preheeters 3. id fsns 4. FD fans f 5. Cold-ges fana

Deslogger The id fans, FD fons Qn colr-gas fans arc to be starte' in zero guide-vane blsde position. The start-ingitself makes the pressure-aide dampera ope After this the furnace preasure is to be adjusted to ubout -7 mm CV/ ond the automatic si^ ste'm keeping it at this value 3 to be adjaated accordingl^. -i-'he dcsla/;,;er is to be operated \vith lov/eat po^ible specd, to keep the weoring at o niniaum and to achieve fovournblc filling of the acroping bladcs of the The speed is changed in dependence upon the osh quantit^ produced,

3.22 Preventilation /Gee:

Work UchecluG "Preventilation and Releaae for Ignition-/

3efore igoition of the oil bumers it is to be enau-red by 3-fold air exchonge in the bciler end flue gaa ducta .that the -furnace is free from i^nitable fuel/air mixture8,.For this purpoae the air dam-pera of the bumers mut be open at abott 30/J TD fen capsciti'. The cold-,:;as fana are to be a'ljustcd to thG air quantity

304832 F N Y V 11.

- 2 2 -

Time of ventilation: 10 min. After ventilotion there is reer^iness for igni-tion for 10 minutes. During this period is thc FD fai copecity to be reiuced to the cooling . stoge, The cold gas quantity is to be reduced to the minimum, Preventilation is to be repeatcd, when 1, the time of readiness for i^nition has expired, 2. ignition has been tried tv/ice in yain,

the C h a i n o f 3ofet ;y -3ystem woald be a^yhov*

i n t e r r u p t e d .

3 . 2 3 I ^ n i t i o n o f o i l f i r i n ^

Vhcn o 1 1 l o c k i n g c o n d i t i o n s o re f a l f i l l e d , the o i l b u r n e r s c a n be i g n i t e d v / i t h i n the i ^ n i t i o n s o f e t y p e r i o d .

ijnition of the first oil bumer it is to be ensured that the IIP reduction station is opened to obt ^0%, becaise the superheaters are flovm through oircady at the initial stage of dcvelop-ment of steam generatlng*

324 Acceleration of the steam /jeneratr In the first phase of the acceleration the number of oil burners resp. the fring itself, are to be limited to a value t wich the flae gas temperature does not exceed 500C before the superhcater sur-faces wich are not yet flovm through. After steam has been developed and abt, 2 bar ar

- 23 -

otill bctore i^nition the condenser shoul be pat ander vocuum, 30 that for the purpose of rcheoter cooling the generoted steam con be guided throuh the IIP reduction station, reheoter and LP by-pass stetion to the condehser. ^ As soon as a steam fTow of - 25 t/h is reached, the firing con be increased to the admissible tempgroture and presoure increose .'^ radienta, /See 3tarting Diogratn and observe trbine conditions./ In the starting phase the water level will rise ;)S a resul t of- expan3on caused by heoting, by drainage through the drum outlet valves the water is to be kept at medium to moximum lovel.

As soon as the starting conditions are givon for the trbine, it msj' be started, *Jefore this the IIP ducts Goding to the turbine are to be varmed up and the fresh Gteam ^olo is to be opened. Aftor load accep-tonce by the turbine further acceleration takes pla-ce according to the admissible gradients of the ele-ments or according to the load schedule, respectively. The pressure is increased to working pressure, Initially, in order to get off the dew point area at the air preheater as soon as possible, only part of the fumace air is supnlied through the flue gas pre-heater, while most of it is guided through the pre-heater by-pass. Only when a flue gas tempersture^f 120C after the preheater is reached, can the air portion flowing through the preheater be increased correspondingiy, hen the air nlet dempers ore en-tirely open, the preheat.er by-pass can be closed.

8M23a VffYV U .

- -

To kaep the flue gaa temperature'at the fle fiaa preheater outlet ver the acid dew pont, the tempereture level is raised tiy recircula-tion of hot air to tho suction side ofthe FD fan.

As 300n 03 we reoch a flae gaa temperoture af-ter the preheater of - 120C and a minimam oil firing of - 20^, coal dust firing can be invol-ved to continue incrcosing of lood/3ee corres-pondirig paragraph "J.V

For putting the first mili into operation, at lotest, the precipitotor is to be 3witched on.

'.Vhen connectin/^ additional milis, heating sim-me tr;y should be achieved, i.e. the aecond aill Ghoald be put into operation immedintelly after the first ene was put undrr load. After otorting up the oil firing is not taken out, os long aa there is no stable cool combus-tion. In the atarting phaae thia is posaible under the following conditions: - At least three milis muat have been in opera-

tion for a time. - = 50-Ca6 boiler load - Correct air aupply with200C air temperature-- Peedweter preheated according to the load. - Frnoce depression at norm;^l fluctvotio^ range.

/

aM252 F N Y V U .

- 25 -

3,3 Puttipg into operation of milis /3ee t)3o Gpecial Directions for d^ill Operotion/

The individaal milis ore pat into operotion as . folloo: 1, T u m on cooling vvater 2, pen locking oir dempers 3, Start mili motor -I Depnfiing of the outlet temperoture of the in-

riivldual raill, add cold gas and hot air in or-der to reduce the increase- in temperature.

5. Open furnace air iam er and adjust minimum air qaantity /abt. 30^ , related to burner capacitj'/ by meana of the re/;ulatins domper.

o. Vhcn the classifier temperature is IIO^C and the starting current of the mili motor ho3 decayed, connect the coal feeder.

7. Adjust the mili load to obt. A0% at first. 8, Oy addition of cold gas and hot air /clasaifier

temperature regulotion/ keep the temperature after the mili in a working range of 130. It ahould be preferred to achieve temperature regulation of the mili by cold gas. An additi-onal cold air aupply to the mili is admissible only es long as no coal is fed into the sys-tem /to preyent eyceeding of the inertiza-tion limit/.

804232 Ft^YV 11.

- 26 -

9 Ificrease mili load occordinf to the o^ aissible operating requirements,

10 Aijust'fuel ond oir in correct proportion a^ eoch burner. ^

11. odmissiblc mili temperature: 210

4. Jtartln;; from warn state

4,1 Hot.sifert V/hen pfitting.tho steam generstor nto oper^tion

t

ogsin DftC'r hort atandotills, e.g. aftcr a breokdown of the plant, high temperotures are to bc reached oiruady with the firat steam e-misLot, in order to prevent thermal shocka - j in the tubes- stili bein^ hot. This requires quick increasin;? of the firinr, capocity to abt. of ter i/;nition of thr oil bumera and early starting of coal Tiring. 3efore ignition the rated pr.cssare value of the IIP reiuction atatflon is adjuated to the ectual value, thus enabling it to open at firat firing and to effect a steam flow

At the reheater side steam flow is to be provi-ded either to the condenaer or ver the roof. 3till before gnition refeeding is necessay, in order to avoid poasible steam emission from the eco during the standstill, Ttfhen the tube duct and trbine temperatures ore reached, the.trbine may be accelerated nnd can accept load.

804232 F N Y V 11.

- 27 -

Vorm ^tart /See Sterting Diagrom/

erm jtarta take ploce after standatills of oeveral hours, e.g, night standstil, when bofor reetortin/^ a minmuni pres^are of 10 bor 3 stili given, but the steam ducts after the stenm "i^enerator have cooled fiown considerably.

3tnrtip,q procgsa:

i-iefeefing*to drura wBter level at lovvest level.

Preventilation: Afljust the rated value of the IIP reduction ata-tion to the actuol volue, thuo enabling it to oppn at first presure increase. Igni tion: Increase the firing copncitj, keeping the ad-missible temperature grodienta- When the con-ditions for starting of the trbine ore given, the trbine can occept load^

804252 VNYV 11.

- 2 8 -

m^ Operation

5.1 Operotin of the gteem /jeneratr The opertion of the oteam generator is to b^ sur-veyed continoasly by the operetine staff Irregulai'ties possibl^ occuring muat be recognize 1 in Lime and corresponding measures must be token, giving priority to the protection of the plant'a components rather than maintaining capacit;y operotion^

*

In general the boiler opertion is regulated outo-meticlly'; required lood changes are effecte^l orj by adjusting.the rcquired capacity value. In spe-cial casee and whn putting the plant into or out of operHtion it is advisabl to operete individaal regulating circuits by hand. The ateom. gene ra tor is opera ted wi th fixed preaau-rn, i.e. the lP outlet pressure ia kcpt constant in the '.vhole opertion lond nree. In oppoaition to this, sliriing presaure conditiona ex3t in the reheater, corresponding to the individual load. The system ia to be fed wi th woter of s quality as per paragraph To mainteln the boiler wa-ter quality a certain quntity s continuously to be elutriated from the dnm. /Observe; NEVER elutriate at the evaporation header during boiler operotion./ 3y injection into the IIP end feheater it is to be enaured that the max admisible steam tem-peraturea are not eyceede at a ^ time.

304292 F N Y V 11.

- 29 -

The rcquired vslues of thc corresponding reguls-ting circuits are to be adjusted occorflinslif.

To influence the reheater temperoture and iajec-ted woter quontty we hove to reglote^the cold-^ s recirculation quantity. v;ith the increosing pollution of the boiler or in cose of majr chon-gflis in the fuel charocteristica readjuatments of thc rated values might bcome necessary,

In coae of sudrlen load chanses or of breakdowns resulting in a considerable change of the ateam

f

temperoture we have to intcrfr bj hond, if ne-cessary. i

5.2 Firin/^ The numbur of milis in operotion dopenda on the boiler losd, coI qurlity and we8rin stote of the milis. At normal coal situgtion full load is operated with 5 milis, V/ith partial loads it is advisoble to lood the fumac equolly, i.e.

4

to chooae a correspofadins mili dombination.

With loads undcr and Iso w^th loa than 3 milis we hsve to work with 10% oil supporting firing, 3upportins firing;^ as alaip applied at ali those states of operation,^ here the combustion becomes irregular. ^

3hould oil firing be involved, when coal operati-on is already on, the operatora have tc convince themaelvea of the unob.jectionabl^ buming of the coal fire directl;y before connection of oil fi-ring.

304252 FPYV 11.

- 30 -

In cose of or^ disturbonce of the coal fire the oil burners must not be ignited.

At loocl the ouperfluous air shall be kept at content efter the furnoce. Ir>-case of

'milis standing stili a small air qaantit^ /abt. 15^ air of the burner corner/ is to be added in order to cool the burner,

3y recirculotion of hot air or vdth the help of the atenm prehenters the rotating preheater in-let temperoture is to be adjusted to

In case of chonged lood it io iraportartt to con-nect or 'lisconnect milis according to the chon-Sed 3tate of operotion in due tme,

V.'hen 3 mili is connocted, odditional heat is ne-cesGorj' to v/arn it up,

5.3 Puttlng a mili oat of oreration m

Dischorge the feeder and distribute the load to other milis, therefore disconnuct the feeder from automatic load regulatlon At the aame time reduce the air auppl^ to the burjer comer in proportion to load distributiov pen the cpld-gaa and hot-air dampers to the mil by When the minimum feeder speed is reached, dia-connect the feeder

U \

8M2M yi>fYV n.

- 31 -

Then 'iisconnect the mili immer^ iotely; the cold-8r floaper to the mili order to open, Clo-se the secondary eir donpers of the burner. /Combustion eir dampcra vithout drive remsin in open position./ ^ Close the locking air decpers. Close the hot-air damper, when the clasoifier out-let temperoture omounts to ^ 150C. .Vith milis out of operotion the cold-gas dampers are to be adjasted to bt. 10% open position, in order to enaure thot the ducts ere not subject to falling below the dew point. About 6 minutes after disconnection of the mili the cold-air dam-per clses.

5.4 '.7et dcaahin;^ The wet deslog^er should in apy case be operated with a lo-.ver HPM, The hi^her RPMs should be uaed onl^ in case of maljor ash quantities*

55 Safety cut-out syatem /See cut-out plana of EYT/ Drawing No. 520/021-01/32 t^

5.36 520/021^8/32 - -

Fire out" Drum W8ter level^^in. "Fire oat" Actaated in case of emergency stopping "Fire out" In case of a breakdovn of both XD

fans and/or both FD fans

M252 F N Y V 11.

- 32 -

" F i r e out** A i r or f l u e gas d u c t s b locked

' ' F i r e out" Furnsce p r e s s u r e < min, or ^ m a y .

L i m i t o f l o a d a b i l i t y :

i n case o f a breal

- -

3witch the prccipitator off. The rotating preheoters continue working; they are put out of operation only at a temperture of

- 34 -

7 General principles for boller opcration To survcy operation and to recocnize irregulerities occuring during boller operation in time, it is indispefcaoble to read and record the most impor-tsnt efficiency factora continuously/*

Ali importont occurencea v/ithin the plant, like break-downs, reodjuotment of equipment, replace-ment of ports, repairs, ete. are to be rtcorded in a shift book of boiler.

Froa the notes it must be posoible to recognize the couse of the break-downs or the reasons of reod-justnents and repairs perfonaed. 3cfore inspecting the plant or parts of it, it muat be ensured thot the apaces to be inspeclod are free from toxic or eyplooive sooes.

At inspectlon of the furnoce t ahould be provided for that no accidents can happen by downfalling ob-jects, slag or oimilar. For lighting of the boller spaces to be inspecte'l and for operation of electric mechinery within the boiler low-voltage equipment /42 V/ is to be used.

^y marking or locking /chain wi^h lock/ it s to be ensured that parts of the plant, wich are to be inspected, will not be subject to dengerous penetration of steam, water, gaa, olB: ete.

t from neighbouring equipment bcing under presaure or in operation.

804S2 F N Y V I I .

- 35 -

After iinspection of the plont or porta of it /air d:wcts, flue gas dacts, ete./ are should be taken that eli objects used for inspection /lamps^ scaffolds, parta, ete./ are daly remo-ved. * ^

*

Prior tlje operation, before locking ali (on ho-les it .must be mafie sure that nobody remoined within the spaces, Re/jlor mantenonce involves thot ali mechani-

t

cal devicea and noving parts are lubricated and t e c t e d in respect of t h e i r wG3ckabi l i ty . Proper lubrication of this equipraent should be checked continuoualy by means of the control eqaipmeht provided /oil level gauges, level indicotors, ete./.

On the basis of this note it will not be nentio-ned in the operation manual that before atorting of each mnchine or other eguipment ia to be checked in respect of aufficient labrication.

The sealing of oll stuffing boxes,^flanges, packings, etc should be checked. For repairs not other msterial than prescribed should be used*

. w 'i-Each time before the plant is pat into operation and during operation, os '.vell^ ' are is to be taken that ali indidating, meaauring and regu-lating devices belonging to the plant and also the snfety and signal equlpaent are road^ r for operation at ony time.

3M22 F N Y V 11.

- 36 -

Cocks, vnives ond goteg are to be oprnerl ond cloaed graduall^ end carefully.

In case. of tvvin fittings those situated at the presure side ore opened first to lOC^, while thoGG aituoted ot-the non-pressure side ore clo-sed first.

In cose of twin fi'ttinga ot the bleedinga and droins alv/a^s the aecond one is to be oct^otcd, whiG the first armatre ot the boiler side re-mains open. The ornoture st the boiler side is to be closed onl^ " in cose of a leakage of the second volve.

tubes arc to be -^ormed up f',rndunlly and to be 'Irnined continuously ot the ir lo-.vest roint,

The proper state of the snfety valves is to be checked fontinuousl:/. Arbitrar^ alterations of the volves, especioll^f their nnt rolization, a-re prohibited.

Domeges are to be elirainoted as soon as possible. In cese of damages involving danger the boiler 3 to be put out of operation immediotely,

Csre shoald be taken that the correct steam valaes are indicatcd onl^ when s^eam is trsns-mitted, i.G. when the saper heters ere flown throagh.

BM292 FN^-V M.

- 37 -

The injection system is to be rnjcls reedy for operation in due" time.

The ateom tcmpero-ire requiped ot the boilur end for connection of the trbine cojj be rea-ched only by loedig the boiler occording to its superheoter chsracteriatics.

I \

l\

u A

aiH2B2 KNYV 11.

A EVT Energe-md /"iVerfahrenstednk

GmbH

P e r m i s s i b l e t e m p e r a t u r e difdPerence between t h e w a l l n i d d l e and i n t e r i o : w a l l s u r f a c e of v a r i o u s e l e m e n t s .

Catalagzi 5.36520/01 ^

Ouuav Hmuflar, Stune

ifl EVT Eherge-und vVVerfahrenstechnic '^JtA. GmbH

?ennissible temperature change l^ '-elocity of various elements. Ctalagzi

5 . 3 6 5 2 0 / 0 1^0

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EN S C O N S O R T I U M F O R A T A L A G Z I P / P T R A N S E L E K T R O K U T L U T A S M I T S U B I S H I CORP SIEMENS/KWU E T M A S

Prepm-e d

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Name S ig^j tre Oote

JLOT T R K Y E E L E K T R K KURUMU

S A N T R A L L A R D A R E S B A K A N L I I

A T A L A G Z I " B 2 s a n t r a l i T H E R M A L PQWER ^LANT g l C e k S C A L E

17- ^TEAI GENERATIIIG UHIT 60. AlR PREHEATER :.Tountig nstructlona

17. GJZPEJLESZT BERENDEZS 60. Lj. L^GHEVIT Helyazini azareleai eloirs

Alt Mteahhidin l&mi I Name af Sub-contrac tor Alt - Mteahhidin Resim M* / Sub-cantractor's (Vwg. N* GDHD N20-73-690'Sz001

Mteahhfdn smi / Name of Contmctor M t e a h h i d i n fiestm N' l Contractor's Drwq N" TRANSELEKTROBUDAPEST Mukavele M a d d e N" / Contract Clause N!

REVIS;3N A C E G K M 0 R T o n c u 1 M o II u

M H D Badapest

|0bjcct: Catalagzi 48o-B2

ubject: Mountlng instructions of Ljungstrm.air heater

Drawing number: N20-73-690-Szoo

Old.-szin: 1

Drawing number: N20-73-690-Szoo s.

23 -JapMl ll

VdU jele: s. 23 -JapMl ll

Tabla of contents

I. General Information 1./ General description of the

equipaent 2*/ General pointa of vew of

monting II Order of meunting

III. oketchea of order of moonting

2 -from 4-to

2 3

3 - 4 3 14 "

15 " 23 "

Vd]h>cok: Kldolgozta EUeatfriztet 2: P1435. 10 000 db ~ 73.73W1 KZl. Ny. 1-38

M H D Budapest

Object: Catalagzi 48o*B2 boller Subject: Mounting instructions of LjungstroiD air heater

Drawing nuober: N2o-?3-69o---Szool

Old.-as&m i 2 M H D

Budapest

Object: Catalagzi 48o*B2 boller Subject: Mounting instructions of LjungstroiD air heater

Drawing nuober: N2o-?3-69o---Szool sssu

....lapbM fiJl

M H D Budapest

Object: Catalagzi 48o*B2 boller Subject: Mounting instructions of LjungstroiD air heater VAlt Jele:

sssu ....lapbM fiJl

I. General Information !/ General descriptien of the eouipment

The construction of the Ljungstrdm air heater i illustrated in Technical Oescription No. N2o-73--69o-Moool and drawing list No. N2o-73*69j2-Boooo and its can be divided into two principal parta:

^ ali stators and the rotor located in these.

a./ Stator The stator essentially conprises the octagonal house, the four supporting leg structures in the lotver part of this, of which two-two opposite to each other connected directly to the supporting steel structure^ two-two connected to the main girder belonging to the stator perpendicularly, and two*two supported points of this ain girder belong to the steel structure.

The four separate flue gas and air inlet and outlet branch systems respectively, are connected to the lower and upper parta of the house. The driv-int gear bracket with the driving gear, the basket sith*drawal door for the dismounting of the baskets on the cold side are to be laeunted on the aide of the house. The inspection, access/ exploaion and asaetdltly doors necessary for operation are located on the branch. The fire->fighting eqipfflent ia to be installed in the upper branch.'

The soot blowRg and ashing equipTOnt ia located below and abeve the rotor, on the flue-gas side of the house. The stator of the lower bearing is lo-cated in the fliain girder, the upper bearing is lo-cated in the upper bridge.

Vultocsuk: o^lgozta: EUentfrizte

P35 . 10 000 d 73.73031 Kozl. Ny. ^ 1 - 3 5

M H D Badapest

Object: Catalagzi 48oB2 boller Subject: dounting instructions of Ljungstrn alr heater

Drawing Duaber: N20-73-690-Szool Vftlt j e l e :

0Id.-8zA: 3

lapb61 AU

b,/ Roter The rotor ersaentially consists of the rotor and the axle systeo built together with this. The rotor 6 a 782o nun-dianeter cylindrical parti its height is 178o ooi/ which consists of the rotor core and the 24 sectors connected to it. In these sectors, at the bottoa are located the 4oo mm high cold-side baskets, 7 in one sector, 168 in ali.

Above this, also 7 baskets per sector and 168 in ali filled vith 9oo mm high wara-8de heating platea are installed.

The load-carrying bearing s located below/ end the radlal bearing is to be found n the upper part. The rotation of the rotor s accemplished by the electroootor via a rod gear located on the outer jacket of the rotor - with the nterposi* tien of a reducing driving gear.

Two electroraotors are installed for the drive one of which is in the reserve, and in the caae of breakdoMi during operation, the emergency so* ter is autoaatically put into operation by a raagnetic clutch.

2./ Beneral peints of wiew ef mounting The order and instructiena of asserably.given in Chapter II are necessary froo the asseobly phase of the connected steel structure and for the lift* nt-n of the individual asserably units of the air heater, and depend on the available lifting mehanisa The following sust be ensured during the asseobly upnerd froo below csentsined in the instrtictions:

V l t o s & s o k : Eldolgozta: EUenfllzte:

P1433. 10 000 a h 73.73tl Kzl. Ny. 1-38

M H D BudapesC

Ofaject: Catalagzi 48e-Ba boller

Subject: Mounting instructions of Ljuhgstro &lr heater

Dranring nosber: i\t2o*73-6go--Szool

OlcL-azftm: 4 Dranring nosber: i\t2o*73-6go-

-Szool Ossa. _ .lapbl li

Vfil 1 jele:

Ossa. _ .lapbl li

a./ If an auto-truck crane vrith 3o m llfting height and having 5o Mp lifting capacity at 8 - I 0 d arm outreach s avallable for the assembly of the air heater/ then the steel structure arount the air heater sust be made up to the + 2^ooo m level. In thls case^ the ndlvidual parts are lifted n frora the space between the rear wall of the boller house and the electrofilter.

b./ If the auto-truck crane ndlcated in peint 'a" s not avallable/ it s necessary to mount a balance bridge having 5o Mp lifting capacity and a sultable nuober of pulley blocks for lifting^ -in on the * 2/00 ra level/ at about lo m height and perpendicularly to the boiler centre en tha part betueen and above the Ljungstrras* Liftifig-ln la accomplished in the space betvveen the tuo LJung-strms by means of the pulley blocks and the vinches

In this space/ the conponents can be lifted above the -I- 21 /00 n level/ then they can be inetalled in the necessary place with the aid of the lift* nt aeohaniana.

VltOEsok: KdoIgozta: EUenAtizte:

P ~ H 3 5 . 10 000 db 73.7S031 KzL Ny. 1-33

M H D Badapest

Objact: Orawing number: Catalagzi 48o-B2 boller N2o-73-69o-Subject: Mounting lastructions of Ljungstroo a ir heater -Szool

VAIc jele:

01d,-az&m: S Ossa.

li

II. Order of nountlng The ordar of aasenbly under the conditiona given in chap-ter I, and ta individual phaaes are contained in the sketches of Chapter III. and they are ndicatad by the seriel numbers wrltten in* In the aketches the ndividtal assembly phases are represented in such a nonner that the parts aiready lifted in are represented by the thinner line; while the thlcker llne indicate the parts to be lif-ted in marked by the serial numbers given there* The in-dividual serial numbers agree with the seriel numbera of the instruetions for the order of assembly given below:

1./ The Ljungstrm air heater ia assembled on the 2/00 m levelj at .525o mm diatance from the rear

wall centre of the boller house towarda the boiler at 9ooo una distance to the right and to tha left froB the centre of the boller* The Joinlag baae le-vel of the air heater is connected exaGtly to the main girders loeated here on the -t- 2o,9& a level.

Assembly should start vrith the checking of the posi-tlon and level of the girder accordlng to the draw^ ig.*After checking. The supporting legs I-II accord-ing to draving No. N2o->73-692-oeoo2 ahould be loeated in the piace indicated in the drawing

2./ The main grder accordlng to draving No. N2o-73^92--oooo4 ahould be lifted in, placed on a^ portiaf feet, they ahoald be levelled with gattge platea and fixed by the given screvs. The poaltion of the pirder aecordlng to the drawing ahould be cheeked, if it is auitable the supporting feet should be elded down accordlng to the draurlng.

Vltozsok: Eidol^ozta: E U e n f i r i z t e :

P155. 10 000 db 73.73031 K6zL Ny. /l-S

M H D Budapesc

Objeet: atalagzl 480-82 boller

Subject: Memting instructlons of Ljungdtrm air heater

Drawing number: N20-73-690--Szool V U t jele:

01d.-BsiD:

Osaa.

li

3./ Supporting legs III

M H D Budapi9t

}b}eet: Catalagzi 48o-B2 boller ^ubject: Mounting nstructions of LjungdtrdiD air heater

Dravylng number N2o-73-e9o--Szool Vfilt jele;

Old.'SZm; 7

a a s . -

lapbl li

Following this, VValls 1,-11.-111,-V ahould be lifted in their places in such a nanner that vievved from the boller, at left-hand air heater No. I Wall II wlth the basket with-dr8w8l door should be looun-ted to\ard9 the boller centre, vrhlle Wall I wlth the driving gear bracket should be mounted on the centre-line of the Ljungstrfli according to opposlte-hand view.

In the case of LJungstrtn No. II, these IValls should be sounted according to opposite-band view, i.e. the basket withdrawal door part should be again towards the boller centre. The Wall parts lifted in should be finally bolted toether, the Upper bridge and the apporting rods should be installed temporarily. The prlnclpal dimenslons of the house, the plane of the flangee and ther parallellsm should be checked.

If ali diaonslons are correct, the vvall cooponents shetfId be welded together finally according to the drawing

Af ter this, the entire tjngstrm house should be levelled with the gauge platea given for the atp-portlfig legs and for the 8U|>port of tho houae, the feet should be bolted down and welded finally.

Then, the Upper bridge and the upper atay re^ should be reffloved for the installation of the Rotor.

7./ Aasenbly of the rotor Rotor eore dranring No. N2O-*73-'694-OO

M H D Budapest

Objct: Catalagzi 48o-B2 boller

Sub]ct: Mounting rratructions of Ljungstro air heater

Drawing number: NZ0-73-690--Szol Vfilf jele:

0Id.-82fita: &

..lapb61 U

The radial plates of the rotor core and the rotor sector ahould be bolted together with the eonnect-ing straps and they ahould be fitted with taper dowel pins. After ali sectors have been placed in, concentricity ahould be checked by a centring de-vice. -The dirving circle parts velded on the site given in dranring No. N2o-73-694-oooo4 oust be also checlced by a centering device before final ^lding-*down.

Safter this, the taper douel pins and bolts should be reiBoved one by one, then the plugs thould be welded n their places according to th drawing and the surface should be :ground smeoth according to need* The 5 mtn radal plates liaiting the sector poarters are fitted together and welded according to the foregoing. Great care should be taken during \yelding to acoid ^rpings and displaceoents. Drawing nuraber: N2o-73-694-ooool. The rotor asseobled in this way should be placed on a stand /bracket/ of such height that it may be possible to install the lower axle.

InatAlation of the lower axle: let ua clean the ro-tor end. aa mil aa the bolt tbreada and the aorfaco of the flange of the stub axle. Let oa grease the bolt threedar let us tighten the bolta vith approKinately lo kpa torque. Then let ua tighten the bolta to approKimately 7o-9o % value of the liiDit of 'elasticity, and let ua bend dom tab ashers* /

I \ The inatallatiofl of the upper axle is acoa4)liahed according to the foregoing*

Vltosfisok: Kldolgozta:

GlleD0rlzte

P14B8. IJOOO db - 71.72051 Kzl. Ny. 1-33 l

M H D Budapei^ t

o b j e c t : Catalagzl 48o*B2 boller Subject: Mounting inBtructlon of Ljungstra alr heater

Draving nusber: Szool VAT jele:

Olrl.-szAta:

saz. ....lapl>61 li

The rotor assembled in this way should be lifted in place by means of a liftlng device in suah a oanner that shelving plate drawing. No. N2o-73-692-ooo2o should be put on the nain girder, then the rotor should be lowered onto this. The lifted-in rotor should be set vertical, and it should be temporarily fixed for further assembly.

8*/ Let us mount the 4 threaded rods on the upper radial airsealing plate, then let us lift it in and fix it.

9./ Let us mount the centering ring en the upper bridge^ let us lift it in place and fit it together rith the house. Let us install the stays as well .

le./ The bearings, the bearing box and its accessories should be cleaned and eiled for the installation of the loner bearing. The pilot bush should be pul-led onto the lower axle. The bearing box together with the bearing /without cover/ should be slipped in place, and it should be lifted with adjusting plates up to the stub axle, so thet the guide base of the loner bearing should bear up on the end of the axle..The pilot bush should be pulled dom as far aa the loner bearing becking, the aealing/ the cever and the dua c^ should be iB

j3bject: C VI l D Catalagz 48o-B2 boller jSubJect: Mountlng nstruction of

Budapest j Ljuhgstra aip heater

3rawing nuraber; -Szool

Vfilt jele:

Old.-ssmj 10 Ossz.

. lapUl] 611

11*/ Let U9 lift in tho upper bearing and momt t accord* ing to drawing No, N2o-73-694-oool7. Let us check the clearance between the shell and the rotor flongeo, Doreover the verticallty of the axle# then It us fix it down with four M24 screw8. The 4 lugs ahould be welded on for the micrometer 8crew in such a sanner that about 1/3 of the thread should stand out. By this fine adjustment it can be ensured wlthln 1-2 mis*

Let us bind up the upper radial plate to the bridge teoporarily for hand rotation, then let us check by hand rotation the clearenees and the correct adjust-oent.

12*/ Let us foount the air sealing drawing No. N2o-73693* -ooool and the regulating equipaent according to drawing No. N2o-73-693-oooo8. Then let us adjust the distance of the radial plates to the rotor by the adjustment of the connecting rods and the threaded rods on the radial air sealing so that itshould be 2 mm below and 3 ana abeve.

13./ The installation of the radial air-sealing reglatr acderding to draving No* N2e-73'-693*oooo6 together with the rod systea connecting the radial plates essentially took place in point 12. ita adjustaent is is done as follovs: First let us put the pin at the end of the connecting rod systen into the aecond bore of the rov of borca of ara iten 2. Let os set 'the edjusting arm n vertical position and adjust the cmntemights so that the radial plates shoud float. If this cannot be done perfectly, than further fine adjustBient can be-accomplished by arn item 25, during which the clear-ances given for the lover and upper radial plates should be aeasured.

Vltooflsok; P KidoltozU: Ellen

M H D Budapesc

Object; Catalagzi 4ao*B2

Subject: Mounting Ratruction of LJungstrda alr heater

Drawing ruraber; N2O-73-690--Szool VUt Jelet

OI(l.-szfi;

li O B S Z .

U

14./ Let us iBount the upper bearing oil indicater accord-ing to drawing No* N2o-73694-ooo49 then let ua fiil the bearing to the given level with oil of the speci-fied grade. Let ua checkwhether the oil level indi-cates the value according to the drawing on the oll-*levjsl indicator. Let us perform this chScking by filling it first to the oinioum, then to the iBexQUffl level with oil and roarking these levelawith a red line on the glass of the oil-level indicator,

15./ The lovver bearing cooling should be mounted according to drawing No. N2o-73694-ooo46. Let us fiil the systen nrith oil of the specified grade so that during filling the oil levels to be seen in lower bearing asseably drawing No. N2o-73-694-ooo29 should be checked first in the slnisuo, then in the maximum position.

16./ Of the sealing sticks item 3 in drawing No- N20-73-694--oooel, the loner ones should be mounted on the lower edges of the radial plates. Then, let us adjust thea so that there should be 2 mm clearancd bet\een the radial plate and the rotor, and then the sealing stick shoold touch the radial plate* Let us fix it in this position by screnrs and by elding at the points given in the dravihg.

V

17./ Let ua install the basket-holding grates in the in-.dividoel seetors.

18./ The installation of the beskets ahould be dene as follovs; the baskets on the warn side should be placed in from above by means of o crane starting fron inside, altemately into the c^posite sectors, so that the loading of the rotor should be unifona. When the parts cevered by the upper bridge are

VdltOKAoc: Sldolgozta: EUenffrizte t

PX4a3. 10 W0 d - 73.73031 KzL Ny. -'1-38

M H D Budapest

Object: Dravying nunber: Catalagzl 48o-B2

Sub]act:M6nting instruction of Ljmgatrs a ir heater Szool Y41t

OIr'.-jjam:

Osaz.

...Iapb61 li

reached, the rotor ahould be turned off by haad to tha exteng neeessary for the lifting^ln of the basket. The baskets on the cold aiede are placed in through the opening of the door according to draw-ing No. N2o-73-692ooolo, by tuming the rotor by hand .to this door in each sector. ^

19./ Of sealing sticks item 3 Inciuded in drawing No. N20-73-694-OOOO/ the upper ones should be mounted on the upper edge of the radial plbtes. After this^ let us adjust then so that there should be 3 mm clearance betveen the radial plate and the rotor, and then the sealing stick should touch the radial plate. Let us fix it by screws and by welding in this position at the peints given in the drawing*

2 0 . / Tha assej^ ly of the air-sealing of the jackets accoapliahed according to drawing No. N2o-73693-oooo3. Its final adjustoent is accofioplished with the-^id of-the adjusting device giben in drawlng No. N2o-73-693-*oool4 in such a manner that the measuring rod should touch the flange of the rotor during the rotation of the rotor.

21./ The soot bloners oare mountet on the flue^s side, on the louer and upper part of the fomse^ reapeotively aeoording to dravring No. N2o-73*695*ooool. The soot blover essentially emsista of te priftcipl parta: the sving pipe vith the parts belonging to it mad the driving gear aystea. After the ^atallation of the sving pipe, let os check by oving it by hand whether the svring pipe can be freely rnoved beteen the two goven end points. After the installaticm of-the driving gear, it should be also checked by eove-

\ ltue^ok; KHnlgozta:

Kilen ffH/te: p1455. - d oag db - ts.tms k z l n y . l - m

M H D Buda pes t

Obloct: Catalagzi 48o-B2

Subject: Mounting instru^tlon of Ljungstrs a ir heater

Orawing nutnber: N20-73-690--Szol VUT Jele

Old.as&a; 13 88Z.

lt

ment by hand whether tfe 8wing pipe moves a so on the path deeribed lr> the foregoing when moved with the driving gear* The adjustment for the above checking sho^ld be done as follovrs: the swlng pipe should be set in one of the dead centres of the 8wing pipe path shown on drawing No. N2o-'73-095-ooool, and arm lo on the rotating joint should be set in the line of this vith the driving gear, by moving it by hand. The aro should be fixed in this position.

22./ The mounting of the driving gear is accomplished according to drawing No. N2o-73-6d4-ooolO/ in the following order: the laotor base and the driving gear frarae should be put on and bolted on temporarily/ the dirving gear, the osotors, the clutches should be put in their place and they should be assembled as indicated in the operating manual of the driving gear*

Let us check it, adjust t with gauge plates according to naedt then let us fix the sotor and the driving gear to the base fraoe. After this, let us looaen the screvvs betueen the base frame and the bracket, so that it Diay be possible to oove the driving gear to gether with the emiklete base fraine sufficiently for the installation of the rod gear* The rod gear should be mounted en the driving gear axle Then, the oooplfite driving gear together with the rod gear should be de-ved and adjustetf, respectively, vertioally and hori-^ zontally wlth gauge plates in saeh a e^nner that bet-ween the driving circle and the rod gear there sheuld be the dloensiHis given in drawin9 No* N2o*73694-> eoolo. Thenf the base fraae should be fixed by screvs.

Vultot^ nlt. Kidolgozta EUen^Trizle:

Pusa. 10 OO b 73.72n31 KOzl. Ny. 1-38

M H D Budapeot

Objeet: Catalagzi 48o*B2

Svb}eot: Mounting inatruction of Ljungstrfli air heater

Drawing number: N20-73-690--Szool

01d.-aKAa: 1 M H D

Budapeot

Objeet: Catalagzi 48o*B2

Svb}eot: Mounting inatruction of Ljungstrfli air heater

Drawing number: N20-73-690--Szool Oaaz.

fiil

M H D Budapeot

Objeet: Catalagzi 48o*B2

Svb}eot: Mounting inatruction of Ljungstrfli air heater V41t jel:

Oaaz.

fiil

The drlvlng gear should be filled wit oil of the grade given in the operating manual of the driving gear to the specified level. After this, it ahould be checked by hand rotation whether the dimenalons given in the above are ensured around the parimeter of the potor.

23*/ Connecting branches draving No. N2o-73-6g2-eool3 should be asseobles in the asseobly area on e plane surface* The supporting pipes should be also installed into the branches, the dimensions should be checked. The branches should be lifted in one by one screwing thea to the house/ then the internal edge of the frane and the screvs should be welded in*

24./ Let U8 Dount the series soot blower according to drauring No N2o-73*695*ooo27.

25./ Let us laount the fire-fighting equipment according to drauring No. N2o-73-6g6ooool.

26./ \Vhen the parts according to the drawing have be in^ stalled/ the radial, peripheral and ]acket air-seal-ing clearances should be adjusted according to the eold State The clearances are ohecked by hand trial retatioo. If the electric oonmotion bas alae taken-placOf then the eleotrio test ahmld be also^erfor-' laed/ and at the same tioe, the oil eysteo ^ f the bear-ingSf the cooling of the lover bearlng, the epera-tien of the ootor of the soot blover stonld be aleo cheeked. If everything s n order, the stili misslng access hole, the observation wln(iow the ezploaion door, the access door, the exploslon-pj*oof lamp should be also nstalled*

Vltozsok: Kldolgxzt: Ellen0rizte:

P1455. 10 MO db - 73.73081 K6zl. N7. l-M

GDHD. Boller Deslgn Office Budapest

Object: ^^ H20-73-690-SZ001 15 GDHD. Boller Deslgn Office Budapest

Subject: Mom-fclng instructions of Ljungs-trm alr heater

H20-73-690-SZ001 GDHD. Boller Deslgn Office Budapest

Subject: Mom-fclng instructions of Ljungs-trm alr heater

Alt. GDHD.

Boller Deslgn Office Budapest

Subject: Mom-fclng instructions of Ljungs-trm alr heater Syatem coae let berB-UH-|

t a

3 -t-

Aitaraton: I liate: ] Slgnsy^et

GDHD. Boller Design Office Budapeat

40u - S2

Subject Mountlng natractlona of Ljungstram air heater

ijrawxng mmiMrt I R 2 0 - 7 3 - 6 9 0 - S A 0 0 1

rf7

SJg

Syaten code lettersvSH

I Date: IS-l^rnntiT**^ Alteration:

GDHD. Boller Deslgn OffIoe Budapest

Objeott 480 - B2 Subjeots Mountlng instructlons of Ljungstrm alr heater

^jrsvJM^ liLuaDVjCi N20-73-690-SZ001

Systeffl oode letters-BH-

1 V ^ 1 r 1 i /\

Al

GDHD, Boller Deslgn Office Budapest

Objectt 480 - B2 Subjeett Momtlng nstructlons of Ijungstrffl alr ho^ter

ijrawng aamoerzt II20-73-690-SB001

et

Sheet

T A1 -^ vMi^ i nnff

6DHD, Boller Besign Office Budapeat

Oblect: vaxaxagzx boller Subjeot; Moontlng nstructlons of Ljungatrm alr heater

Drawlg numbert ir20-73-690-Sz001 Alt.

1 9

Sheet Syfltem code letters-Bd'

Alterations

GDHD. Boller Deslgu Office Budapest

Catalagzl 480 -B2 01)3 eot boller Drawlng numbert 120-73-690-SZ001 Side 20. GDHD.

Boller Deslgu Office Budapest Subjeot: Mountlng nstructlons of Ljungstrm alr heater

Drawlng numbert 120-73-690-SZ001 Sheet GDHD. Boller Deslgu Office Budapest

Subjeot: Mountlng nstructlons of Ljungstrm alr heater M M

Sheet GDHD. Boller Deslgu Office Budapest Subjeot: Mountlng nstructlons of Ljungstrm alr heater System code ] Le cters-jstt -

GDHD. Boller Design OffIoe Budapest

ODjeot: Uataiagz - d boller Subj eot: Moutlng nstruGtlons of Ljun^rm air heater

prawlng numbert ]20-73-690-SZ001

Slot 21 sneat

System oode letters-NH-

6DHD. Boller Desi^ Offioe Budapest

Objeott Catal^gzl 480 - B2 boller Subjectt Motntlng natructlons of Ljungatrm air heater

Drawlng number: II20-73-690-SZ001

Side t 22 Shee

yatem code letters-^-

Zt-Aitftfnation

GBHD. Boller Doalng OffIoe Budapest

Objeot aiiaiagisl 4au - B Subject: Mouniig nstractionfl of Ljungstrm alr haater

roswiHgTnnrTOrr" I T 2 0 - 7 3 - 6 9 0 - S Z 0 0 1

SJ5 es Sheet

System code letters-HH-

Ac/jus/znen/ c/eoronce in cold sioie: _ A - ^ mm D = 4 mm 8=0 mm E mm C ^OtSmm F - S mm

T T TsT -

ANGOL

TR B U T 10 N 3

TR B U T 10 N

C EK B E A 1C R e v C h e c k e d O a t e N a t u r e of R e v s o n :u .EMENS WU

C O N S O R T I U M F O R A T A L A Z I P/P TRANSELEKTRO KUTLUTAS MITSUBISHI CORP SIEMENS/KWU ETMA5

THA S Prepofe d d r a w n

Checked Approved

Name hiUnka^ ^atc

Kalor yt^ fc^

S ign oture S

Date

fii.or TRKYE ELEKTRK KURUMU

SANTRALLAR DARES BAKANL

A T A L A G Z I - B 2 TERMtK SANTRAL THERMAL POWER PLANT CLcEK s c a l e

17. STBAM GESmASmO umi 60* AIR PRmEAm OpMatAg and oalntananoe Znatmustlona

17. aZFBLJESZ BEHSUDEZS L^.LSHEVIT zeaeltetal, karbaatactaal utaaita

Alf - Mteahhidin smi / Name of Sub-controctor Al - Mteahhidin Resim h / Sub-confractor's drwg. 1 GDHD N20-73-690-K0001

Mutefihdn smi I Namt^ of Cantractof Mteahhidin Res im N / Contractor's Drwq N TRANSELEKTROiBUDAPEST Mukavele M a d d e fl / Contract Clause N

REV15I0K M

GDH D Bndapest

Ob^ect: Bollar Gatalagzi +80-B2 Operatlng and aalntenanoe InstruotloiB

KOOOl

Vlt jele:

Old.-szm:

1 Ossa.

!l3.Lpb6l fiil

Systen code letters: - IH

Paginatlon

II

TA3L3 Qg CQM?Bira3

Operatin^ ;^n^ p-^ :-r'uotlonB 1. Tasks prlor to putting

tha ogulpaant into opaMtioB 2. Putting tJo oquipnent nto

operatlon

3 'Paska durlog the operation 4 Stoppig and putting out of

oporation

Malntenanoe natructlona 1. Maintananca of heaatlng platea 2# -Ialatenance of air aealinga 3. .Maintenance of drives

I.iaintananca of baaringa 5* Maintenance of cleanlng and

fire-estlnguislin^ eqvl|wents 2nuaeratlon of lubrloatlng polnts and lubrleants

3-4

5-6 7-8

9.

10-13-U-15. 16-22. 23-27..

27.

27-28.

III. Oparatlng and mainteaanca plana and dyawinga Skatah HTo. 1 - ^'low-diagra of flua gaa 29-

and air systea Skotfli Ko. 2 - Flow-Hiagran of purging systen 30-31-Sketch Ho, 3 - ?low-diagram of flra-eztingulsh- 32.

ng aystan Slcatch Ho. 4 - Schaa of tuba-oil and cooling 33.

aya t an for L;]ungstr2i*s baarluga

VltOK&sok: l

Kdolgazta: U i EUenffrlate:

P1433. O 000 db 73.7X1X KzL Ny. 1-S8 A

6DH D Budapedt

Object: Boller Catala^al 480-32 Operating and oalntanance lstructlos

N2O-73-69O-COOOl

Vftlt jelet

2 o s a .

45apb61 611

^ystea code letterss - HH

Skotch No. 5 - Plan of adjustnent gap values rolatod to tho oold stata of the alr sealiogs ^

Sketch Ho. 6

Slcetch IIo. 7

Sketch lo. 8 Sketch IIo. 9

Plan of replacins the taaket at the wara side Plan of roplacing the "basket at the cold side Plan of replaclng tho drlve Plan of replacing the lower "boaring

34.

35-37.

38-39,

40-41

42-43

:20~73-O93-0001

20-73-693-00002 x20-73-^93-0003

if20-73-694-00010 II20-73-69#-0017 I20-73-$94-00029 N20-73-694-00043

1120-73-694-00049 I20-73-69 5-00001

iladial alr aealinga Oircuafarential alr SQ.iJiss Liaatle alr seallngs Asseably drawins of drlve Assembly drawiog of upper bearing Assenbly draw1ng of lower baaring Aasembly drawla of bearlng ooollnf systea O H lavel indloator pf upper bearln^ Aisseably drawiTig of soot blowers.

5 Vltmok: KldolgozU EUeafltiaie:

p 1 3 . looo - 73.7w31 k b z . n y . 1-m

GDH D Badapest

Objaot: Boller Gatala^zl 48o-B2 Operatln^ and oalntenanoe Inatmotlona

K O O O l GDH D Badapest

Objaot: Boller Gatala^zl 48o-B2 Operatln^ and oalntenanoe Inatmotlona

K O O O l Ossa.

Iapl>61 &11

GDH D Badapest

Objaot: Boller Gatala^zl 48o-B2 Operatln^ and oalntenanoe Inatmotlona T4U

Jele:

Ossa.

Iapl>61 &11

System ooda letters -m

1. Taalca prlor to nuttlng the opulpment lato oporatlon ^ Taska prlor to puttias the oguipnont Into opo-ration, ara dotenalaed ,by "bh. natura of stopplngo Accordlos "to tha aature of atoppiag the ohook oaa be categorized as follows: !! the ohecJc to be performed subseguently to

the first and general repairs 12 the partlal oheclc.

1.1 Ghack to be parfpraed aubaaauenti? to tha firgt and -general repaira The nature of oheolc t o be perfonaod sub3aquent7 to tha first and general repaira is detaraiaded by tha quantlt7 of diamantled, i.e. rapalred subaaaembliea. Taking into aooount thla oircua-atanoe the workng order of air heatar haa to be oheoked n eaoh oaae. The oheok have to be perforaed aooordlng to the folloiTns naB oonalderatlcma a*/ Prlor t o nstalllng and oloalag down the

mouatln^y doors* the nanhcles and the ns-peotlon doora verlfy the orreot noorporatlon aooording t o the relevant drawTig> Make s w e that no forelga naterlal haa renained n the alr heater.

V&ltoesok: KidoIgoaUt

Elleaffrlzte: l P1455. 10 OM db 73-7ai KzL Ny. 1-S8

GDH D Budapeat

OTjjeot: Boller Catalagzi 480-32 9paratlng and laalntenance lastruotlons.

T20-73-690-KOOOl

Vlt Jele

OId.*fzAa

4 Oasa. -..Japbl li

Systen oode letters - m

b./ Vorify the gap valuss related to the oold atata of alr aeallngs reprasonted s ths skatoh I^ o* 5*

Om/ Vorify the oll lovel of drivo boarlngs, in the case of neoassity raflll to tha praaorlbad laval*

d./ Verify tha ooollng systen of baarings. If t s in order, start tha olllng systaa of Iower baarla^.

a . / T u m rotor of alr heater by hand. If it la n ordar, swltoh-on the dr ive of alr heatar*

In tha case where the alr heatar s in full worklns order, close down ali the somtlns doors, nanholos and inspeotlon doors ad contlnue or stop the ezplotatlon accordins to the startlns condltlons of boller.

12 Perfom tha detall ohaolc durlng the operatlon or at stoppins aa aqttlpmant tostrallad outside of the alr ho^ar* a./ Tha paragraph 3 spaoifles tha oheok reqlra<

duriB the operatlon* b/ In the case whero tha aqlpaent oones to a

stand-stUl ovrin^ to the oausas outsida of the alr hatar t s supposed that tha alr heater be n orklns order end tha rastart-

k i d o l ^ o z u t v l t o & s n k : EUenArUta*. y 10 000 a b - 73.t0ai k z l n y . 1-s

GDH D Budapest

Objoi;: Boilor Catalagzi 48-32 Operating and maintonanoa Inatruotlons

1120-73-694-KOOOl

Tlt jela:

5 Osiia. ...iapbtfI ll

Systen oodo letterss -NH

ng oold "bo perforaod wtiln a ahort tlaa In thd aforesald oondltlons we don't dlsmantla tha air hsator but wq nspsot only tha parts v M c h oan be eraalndod and oJaeoked^in tho iyorkiig ordor* Eaontially V7a ara talklns about a safety oheck inoludlng the ohookln^ of the gapa of air geaHngfl of tlo oloaalineas of tho heatln^ platoB, of tho oil level and of oil filltara. n fuaotlon of tho aTallable tlae*

2. Puttlng Into oparatloa The air heatar ha'a t o be a t art ad prior t o putting tho fana into aervioe, n fonforalty witt the atErtlnc 30quanoa of the main aquipaanta of bollar n the nannor apeoiflad herelnaftart

2.1, L^djtst tha olllns ^ ^ ooolia^ ayataia of bearln^a ropreaanted in the aketch lTo.4 to poaition "oparation" and atart tha oil purap. Aftar atarting oheck tha workin5 order of ooollns and oillns ayatera

22. Start tho drlve of air heater. Cheak the sense of rotatlon beli olookvrise loolcLzg lA froa abore. VThen the rotor has attained the operatlonal 1,3 rpa, eheok the anereneter of driviz^ motor vhloh has to ndioate at a eurreat oonaumptloa lower than 2G aapere* la the ease whore the oorrent oonauraption ezeeeds this value one murfe deteot the oause of fault*

kldolgozta: OjLLtfiC v d l t o a a o k :

EUeBtfrlte: a p1435. 10 oao d b 73.73091 k z l n y . 1-38

6DH D Budapesc

Object: Bollar Catala^zl 480-B2 Operatin and fflaiateaaao.a Inatmetlono.

N20-73--69O-KOOOl

Vlt jele:

OlfL-szin

Osac.

lapUl ll

Systea oode letters:

In the majority of oausea tha aJ^orasald troubls s cauad by tha alaadjuataoat of drlve or of alr sealln^s. Tha dataotad fault haa to ba allmlnfttad, Xt s allovrad to put Into service excluslvely a trouble-free eqxalpaent.

2.3 Hareupon oheclc tha "avallablllty" of purglns systam represanted la tha sketoh ^o. 2 and of fira axtlagulah1 ng systam represanted n tha slcetoh No. 3.

2.4 Chaok tha "startng" posltlon of danpars sl-tuatad around tha alr haatar raprasantad a tha sketoh No. 1. Haraupon prooaad n tha manner speclfled haralnaftar. Malntaln tha "startlng" posltlon of danpars as lon^ as tha flue gas taaperatura aftar tha alr haatar raaches 120 C and tha bollar ope-ratas by maans of tha Igni.tlon o U bumas. Prlor to Ignltlag tha pulvarlaad ooal bumars start tha other alr haatar out of serrloe and haraupon adjust tha danpara of flua gas and alr aystaa lnol\3dJ.ng tha relayant fana aad represanted n tha sketeh Ho.l to "oparatlaK^" poaltlon and upkeep n thla maznar until tha 50 par oent loartlng of bollar. Heveupon adjuat tha danpara of flue gas and alr syaten t o tha aarrlaa condltlons oharaetar-zad by operatlng tt^ o F.D. fana and fana, aoeordlng to tha aarvlea inatruetlona of fana.

v i t o b s o k :

p--14m. 10 000 db - 73.to81 k z l n y . j-s8

6DH D BndapesC

ObjootJ Boller Gatalagzi 480-B2 Operatlng and malnteuanoo Instruotlo2ig

H20-73-690. KOOOl

Vlt jele:

0 1 d . - s z a m :

7 Ossa.

..Iapb61 fiil

Systea oode lattarss

3. ^aaka durlng the oparatlon ^he taska to be perforaed durlng tho oporatlon oan be eatasorlzed lato tle follow2i two groupst

31 Cheo^ of operatla^ condltlona related to alr :ii9ater. 3*2 lrouble-ahootlng o air heater* 3*1 The operatlng condltloas related to alr leater oan

be cheolced praotloally by a visual nspeotion and by ocntrolllng the incorporated Instruments n the manner speolfled herelnafter: oheok the o U level - cheok the noorporated theraoraenters - oheok the drau^t met er s - oheok the CO^ and meters - oheok the tempereatre of bearinga nooporated

Into the drlve gear of alr heater - aoot-blowln5 af ter eaoh 3 hours approacLmatelj-

3*2 ^ e trouble-shootlng has to be pe^formed in the oozrse ofi^the aforesald oheokln^. The oheckln^ have to be extended to the eoaplete egulpaeat taklng into aocount the followji laportant eoaslderation

If the teaporature of bearin^a esoeeds 40 ^C and it la raisin^, ene must deteet the ease ot faalt*

v l t o b i s o k : Kidolgozta:

EUantfrbK: p1u9. x0 eoo db ta.tso&l k z l n y . 1 - n

G D U D Objeot Boller Catalagzi 480-B2 N20-73-690-

KOOOl OIcL-zAm:

3 Badapeat Operating and naintenonoe

Ossa. Badapeat Instruotlons Vdit jelo: .,..lapb61 li

Sesten oode lottera -HH,

- If the Qxlt alr tamperatre is raiaio^ sd-danly aa oompaxod t o tho operatins tompera-ture ne miat oantrol w]eter no firo bas brolcen out n the atr heatar. In the case of observing a brand one must adjust tho fire 9xtaguishlng aystem represented in the sketoh Ho 3 to "fire ertinsulahing" position.

- If the resistance at the flue gas aide in-oreaaes about by 13 to 20 TtmOm ma, renove the deposit froa the heating plates by means of oleaning systen represented in the alcetoh Ho. 2.

- If the O2 and COg doTate froa the presoribed serrice oonditiona, i.e. after the alr heater the CO^-reduction exceeds 1 per oent under the 100 per oent boller loading oheok. the alr aealing and adjust thea in the oaae of neoeasity Q?ha oirouaferential air sealin^s oan be re-adjuated ezeluaively to position out of sor* Tiee.

- la the oase of hearing an abaossaal friotion in the air heater or a bloif'^ lilco sound n the stielc gear oatlag nspeet the air heater /depending an the deteeted faul t/ also nside at the position out of serTGe, reveal the eause of friotion and ellminate it Check The stlolc ;ear oatlng and ellminate the blow by neans of a oorreot adjusnent.

Vltoesok: k i d o g a z t e t

EUeaffriata: 2 P1433. 10 000 db 73, im KzL Ny.

GDH D Budapest

Objaot* Bol lar Catalagzi 480-B2 Oparatins and malntenanoa Inatruot iona.

KOOOl OIcU-czim:| 9 GDH D

Budapest Objaot* Bol lar Catalagzi 480-B2 Oparatins and malntenanoa Inatruot iona.

KOOOl Osss. ..lapbAl 611

GDH D Budapest

Objaot* Bol lar Catalagzi 480-B2 Oparatins and malntenanoa Inatruot iona. Tt

Osss. ..lapbAl 611

Syate oode l o t t e r s :

4 . StoppJig and puttlag out of oporatlon Ag regards tho nautro of stopplng i t oan ba o a t e -gorlzed l a tho followTTg mannert ^

- a s-tands-tUl of short duratlont - a porzaanont atopplns, l e . tho putting out of

operatlon.

In both cases porfona a soot bIowlng p r l o r t o stopplog and prooaed n the manner spoolfled h e r o i n a f t e r ,

4 a Standfltll l of alort duratlon

In t l ls oase the a i r heator has t o be in sarvloe readiness, l . a . n tha oandltlons ragulrad for the r e a t a r t l n ^ . Bependlng on the dratlon of s t a n d s t i l l tha oi l lng and tha baarlng oooling syaten remain n working ordar axcapt tha a l x heatar and tha daapars.

4 . 2 Parmanant atopplng

In the oeLse of pemanent stoppin^ put the air heatar and ali its aooessoriea out of serrloe. In the oaae of dan^ar of frost dewater the baarlns eoolins syatea, the fire extiBgulshlng aystem, the waflhln systea and the olaanlng aystra* Perfozn the required repalra aa wall as replaoe the air seallnsa and tha haatla^ plates aooordinc t o the para^raph I I .

Vltos^olr: KldoIgozU EUenStitte:

4. pma. - 10 000 ab - 73.Tm k2l Ny. -aa

GDH D Badapest

Ob^eot Bollar Catala^zi 40O-B2 Operating and malntenflnoe Instmotlons

I2O-73-90-KOOOl

VMt Jele

OIfL*0z6m: lo Ossz.

. . . l a ^ li

Systea eode lettars; ^BH

I. ^^ T^ -faAA^ f? hlff^ ^^ T^ Plataa The malntaanoe of heatjjg platas^inoludes the oleanTig and tha replaoement aooordlng to tha followlng speolfloatlon.

I.l ojg Undor tle oloanlng of hoatlns plates we undar-stand the soot 'blowlns and the vyaaMnge fhe _aoot blo^rt^ la a mantananoe to be perfoasaod duping tla op arat lan dopandlng oonsiderably on tLo solllng of laating platos* Ganarally tha oparatlon of soot biovtera ara af t ar aaoh 3 houra neoaasary. (Tha daflnlte achadula haa t o bo d r a m up on tha basla of wxperlanoas obtained drlzs tha oparatlona. Tha skatoh No. 2 oontalza tha sohaaa of a o ot blowlzxs aystam. Tha sootlaLowln3 has to bo par-foraad n tha folloylng naanars Adjuat tha valva of tha lower soot blowlng sys-taoi to "oparatlng" posltlon and start tha dr7-ns motor of soot blower Operato tha Iower soot blowar unlt for 35 nlnutas. Horov^oa start the uppar soot blowar mlt and oparata it also for 55 alnutas.

V&lunisok: Kdolgozta EUentf rlte: t P-140. 10 000 db - 73.7081 Kzl. Ny. l-M

GDH D Budapet

Objact Bollar Catalagzl 480-32 Operatlos and. malntananoe Inatruotlons

1I20-.73-69O-0001

OlLazAm: 11 GDH D

Budapet

Objact Bollar Catalagzl 480-32 Operatlos and. malntananoe Inatruotlons

1I20-.73-69O-0001 Oftas.

ll

GDH D Budapet

Objact Bollar Catalagzl 480-32 Operatlos and. malntananoe Inatruotlons Vlt jele:

Oftas.

ll -Systea oodd latters: -HH

ffashija of heatlna aurfaoes of al> heater Gleanlng prooess out of operatinn. !I7he frequ9no7 of wanh1ng oamot be pre^oterainsd as t dapends oanslderably on the fuel, on tlo gmlity of depoait, on the froquenoy of restart-ng and i^ltlon, l.e on tha natura ofoporatlon, at e For that reason tlo waahlng b parforaod tn tha oasa wlira the dlrt oaanot bo remora by soot blowins. The skdtch no.2 ocntalns tha fXow-dlasraa of waahing aqiLpaent. ParfoOT tha mahing n the followiag manaart - J?or tha duratlon of waflhln5 shut-off tha alr

haatdP out of flue ^as and alr ourrent by means of darapera placad baforo and aftar tha air haat-ar l.a. put t out of aarrlca.

- Opan tha sllda-Talyas of waahlng Y7atar abductlon systaiB sltuatad at tha alr slda below tha alr haatar.

Disnomt tha jolnt of fly-aah raacrrlns erlpaaat plaoad an tha hoppar of tha flue gas duet belov the alr heat ar and nat al the washBS water ab-duotlOB syatea*

- Prloar to mtshijss put the drTns^ear of alr heatar Into servloe* fiotate the motor durlns the vvashln^, le. operate t.

- Swltoh-Km the drivlag notor of lowar and :^ E>per washing unlt.

v l t o b & o k : k l d o l g o z u :

EUentfizte:

p1433. 10 000 db 73.tms1 k z l n y . t-sfl

GDH D Budapest

Objoot Boller Gatalagzi 4BO-.B2 Oparatlng and maintonaaoo Instruotlous

KOOOl VUt je0i

12. Ossa.

..-lapb^l fiil

Systom oode lotterss - M

- Adjtial; to "operatlng" posltlon, l.e.opoB tla valvas of washing systom represontad n sketoh no2*

- Mjst to "operating" position, ie.^opa the Y073S of llne fluaher.

- Oontlnu9 tha wanh1.ng until the alkallnlty of flowlng awa7 wate7 reduoes to about 7 pH This onaues after the waah1ns wa3 perforaed for about 8 houra but t deponda on the ertent of aoUlnse

- Aftar the vashlng was flnlshed adjust the waahlng wator abduotlon aystem t o posltlon antlolpatln^ the elutlzm, la to poaltlon oorreapondlng to the aar