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PROJECT TITLE
VIETNAM OIL AND GAS GROUP (PVN) FICHTNER GmbH & Co. KG PV ENGINEERING
INSTRUCTION MANUAL
22.06.2018
FOR THERMO PROBE
CHECKED T.G.LEE
DIAMOND TP500-E
THERMOPROBE
Temperature Sensor
Contract N11836
www.diamondpower.co.uk
OPERATIONAL WARNING
When the blower is in operation, or during installation testing,
Steam, Hot Gases or Ash may, due to the nature of the process, be ejected in the
vicinity of the sootblower
Surfaces of the Wallbox, Poppet Valve and the Sootblower Lance can be very hot to
the touch during operation and PPE must be used at ALL times in the vicinity of the
Sootblower
Unit
Position No. Serial No. Tag No.
Number
--- B79361 1 P1HBK10CT001
---
--- B79362 1 P1HBK10CT002
Equipment Supplied
4 Off TP500-E
Revisions
2.1 Introduction
The TP500-E Thermoprobe is a mechanical device for positioning a thermocouple element in the furnace
gas stream for temperature monitoring. The thermocouple is mounted on the end of a probe tube which
traverses into and out of the gas stream.
The probe tube is attached to an electrically-driven travelling carriage which incorporates dual rack-and-
pinion drive.
The TP500-E permits continuous monitoring of the gas temperatures in the critical area just ahead of the
Reheater tubes at the exit of the furnace. Constant temperature control in this area reduces the danger of
heat damage to the tubes during boiler start-up before steam circulation is sufficient for cooling. The unit
can also be used to obtain gas temperatures which are used as an aid in controlling low-load operation.
2.4 Application
The TP500-E is suitable for use as a start-up device in gas temperatures of up to 815°C and has a
maximum travel of 10.97m. When travel exceeds 7.6m the probe may sag due to the unsupported
section of the probe tube. This would cause the probe to deflect from its horizontal path. To ensure this
does not happen an additional support is added on the underside of the beam. To view a schematic of this
assembly please Refer to Section 7.13 for a diagram of the assembly.
WARNING
THERMOPROBE
2.6 Operation
The thermoprobe is controlled by limit switches mounted on the carriage and actuated by a series of
triggers mounted on the thermoprobe beam. When the carriage reaches the limit of its forward travel it
makes contact with the reverse trigger. This action reverses the drive motor and retracts the thermoprobe.
When the carriage reaches the cooling medium limit switch it will either carry on to its fully retracted
position or repeat the cycle again depending on the signal from the DCS panel. When the thermoprobe
completes its cycle the carriage makes contact with the reset trigger and stops the motor.
During the cycle, the thermoprobe‘s position is constantly monitored with a position transmitter. An
encoder counts the teeth of a pinion drive allowing the exact position of the probe to be known at any point
during the cycle.
The Electrical wiring diagram is located at the end of the Instruction Manual
3.1 Mechanical
The TP500-E Thermoprobe comprises a number of sub-assemblies as described in this section.
A comprehensive breakdown of the components is given in Parts Identification section.
3.2 Beam
The beam comprises a folded steel canopy onto which is welded, a front bulkhead plate.
The front bulkhead plate carries a roller assembly to support the probe tube. A rear support plate, bolted
to the front end, acts as a blanking plate for the canopy assembly. Four angle brackets, welded to the
canopy sides, support the carriage, via carriage rollers. Gear racks, attached to the upper angles, engage
with carriage pinions to provide travel.
The beam is supported at the front by a wallbox and wallsleeve. Bolts connect the wallbox to the front
support plate. Rear support is provided by a rear support assembly mounted to the installation structural
steelwork.
This method of suspension allows the thermoprobe to take the expansion and contraction of the boiler in
three planes.
Beam Assembly
Rack
Assembly Front
Bulkhead
Wallbox Support
Pin
Probe Tube
Seal Plate
To Boiler
Flange
Assembly
Screwed Rods
Rear Support Bar
Support Lugs
Beam
Carriage Operation
Gearbox
Rack
Drive Motor
Support Roller
Fabricated Chassis
Energy Chain
The Energy Chain cable arrangement transmits power from the terminal box located on the side of the
beam to the drive motor,limit and proximity switches. The cables are housed within a powerlink energy
chain arrangement, one end of which is mounted to the carriage with the other end fitted to a plate located
on the beam.
Terminal Box
Rear Support
Assembly
Tow Bracket
Limit Switch
Carriage
Mounting
Chassis
Mounting Rail
(Fixed to Beam
at Front)
Trip Plate
Front Operating
Limit Switch
Support Bracket
Rear Operating
Limit Switch
Mounting Rail
(Fixed to Beam at Rear)
Motor
Gearbox
Trigger Wheel
(4 Tooth Pinion)
Probe
Tube
A position transmitter proximity switch is mounted on the gearbox mounting bracket to provide an
accurate feedback on the position of the probe within the boiler.
A four toothed trigger wheel is attached to the gearbox extended shaft. The pulse count proximity switch
detects the movement of the teeth and the signal is fed to a counter unit which calculates the probe
position which can be displayed on an appropriate LCD.
Note. Refer to the Thermoprobe wiring diagram of Section 10. TECHNICAL DATA SHEETS.
Probe Tube
Air Outlets
Gland Adaptor
Thermocouple
Lead Wire
Tip Shield
Follower
Manifold
The probe tube consists of a thermocouple, stainless steel tube and manifold. It is mounted to the front of
the tube and is enclosed within a protective shield which is threaded for attachment to the tube. Leads
from the thermocouple run through the probe tube to a junction box located on the side of the fabricated
carriage chassis. The leads are ceramically insulated and enclosed within the steel tubing throughout their
length. The rear of the probe tube is sealed with a gland.
The cables from the junction box are fed to the beam mounted starter panel through the energy chain.
When air cooling is required, air cooling inlets are provided at the manifold. The cooling air flows through
the thermoprobe and escapes through nozzles situated near the probe tip.
Air Hoses
Solenoid Valve
Air Pressure
Flow
Switch
Regulating
Valve
Caution: Do not use a sling around the beam or the protruding probe tube, as this may cause
damage and subsequent malfunctioning.
Lift the thermoprobe into position using the lifting lugs provided on top of the beam.
Fit the thermoprobe to the wallbox, locating the mounting pins and spacers correctly.
Connect the sealing air pipework to the wallbox. (Positive pressure applications only)
The cooling air supply must be connected to the hose fitting on the stationary manifold assembly, when
applicable.
Observe the alignment of the beam arrangement: check for any bends, twists or other distortions.
Make the power and control connections to the thermoprobe terminal box; ensure that there are no loose
terminals or wiring. Leave the thermoprobe ready for commissioning.
Cotter Pin
Washer
Note:
Fit guards (When Applicable) after commissioning. (Refer to installation drawing - Technical Data Section)
Fill carriage with appropriate amount of oil before proceeding, refer to lubrication section.
Electrical Connections
Make the power and control connections. Refer to wiring diagram and Control Systems Interconnection
diagram.
The motor current on the spec sheet is approximate and will depend upon many factors
(voltage, installation, tightness of wallbox, packing and gland tightness etc.)
If the current varies greatly, address these areas.
Winder Adaptor
Air Wrench
Hexagonal Bit
Warning:
It is essential to keep the cooling air supply ‘ON’ to cool the probe tube until it is retracted.
The thermoprobe must always be returned to the fully retracted position after manual operation to
reset the limit switches.
Operate the thermoprobe manually and check that all of the mechanisms function correctly.
Operate the thermoprobe from the local push-button (where fitted) to check the direction of travel and the
operation of the limit switches; repeat from the remote control panel.
Operate the thermoprobe with the cooling air 'ON'. Check for leaks and rectify as necessary.
Set the Wallbox Sealing Pressure, where applicable. This can only be carried out with the boiler on-load.
The thermoprobe should be operated through several complete cycles, with the cooling air on, to check
that it is functioning correctly before finally putting it into service.
5.4 Maintenance
Operational Checks Periodic Inspection
The thermoprobe should be inspected periodically to ensure that:
All mechanisms are functioning correctly.
All moving parts on the carriage are adequately lubricated with recommended lubricants.
Thermocouple tip and probe tube are in good condition.
Limit switches, proximity switch and electric motor are operating correctly.
Power and control cable run smoothly within the energy chain arrangement during forward and reverse
travel of the carriage.
The front roller is adequately lubricated.
The frequency of inspection will depend on operating conditions, but should be at least once a month.
Annual Maintenance
The thermoprobe should be inspected annually for deterioration of all critical parts; these should be
renewed, where necessary. Mechanisms should be checked and adjusted, where necessary.
Critical parts include, but are not limited to, the following:
Rack and pinion.
Support Rollers.
Limit and proximity Switches.
Manual Operation for Setup or System Check
All thermoprobes can be operated manually by attaching a ratchet wrench to the winder adapter on the
extended drive gearbox shaft. Refer to section 4.3.
If a fault develops with a set of thermoprobes during automatic sequential operation, the thermoprobes
should retract automatically. If they fail to do so for any reason, such as power failure, motor stalled, etc.,
immediate action must be taken to withdraw the thermoprobes involved.
Adapter Tool
Hexagonal Bit
Air Drill Purchased Separately
Purchased Separately (Part No. 399222-000A)
(Part No. 909305-8910)
Adapter Tool
(Supplied with
Thermoprobe)
General Lubrication
The gearbox on the carriage is a sealed for life unit and if necessary should be replaced and not
refurbished.
The bearing shaft is fitted with “sealed for life” bearings and require no further lubrication. When worn they
should be replaced.
If any bolts are temporaily removed from the thermoprobe, the heads and threads should be coated with
an anti-seize compound such as Molykote G or Thread-Gard before replacement.
Apply a light coating of oil on a regular basis. No NOT overload as this can attract dirt which could have a
detrimental effect on the carriage movement.
In situations where the atmosphere contains a significant amount of ash or dust, Mobilgrease Special
should be replaced with a synthetic oil such as Royal Purple ™
http://www.royalpurple.co.uk/royal-purple-industrial.html
“Synerlec® is Royal Purple's proprietary, lubricant additive technology that strengthens the oil film to
provide extra protection and performance.
Royal Purple continuously protects because Synerlec® continuously adheres to metal parts — even after
shutdown. The thin film of oil that remains after shutdown preserves parts and provides instant lubrication
at start-up until a full fluid oil film can be established.”
Royale Purple runs clean and does not attract dirt.
Apply fresh Royal Purple ™ every month or 100 cycles.
Thermoprobe fails Limit switch or Proximity Switch fault. Check the trip lever or actuator
to stop. operates the switch.
Renew the switch if necessary.
Probe tube Auxiliary support (If fitted) out of alignment. Loosen cap screws and re-
tracking position auxiliary support.
incorrectly.
Position transmitter Gap between switch and trigger wheel pinion Re-set gap to 0.1 – 1.0mm.
does not register. incorrect.
Limit/proximity switch defective. Fit new switch.
Wiring fault. Check wiring.
Removal
Ensure that the thermoprobe is in the fully-retracted position.
Disconnect the thermoprobe from the power supply.
Fit the lifting equipment to the four lifting lugs provided on top of the beam.
Disconnect the electrical cables as necessary to permit removal of the thermoprobe.
Take the weight of the thermoprobe.
At the rear support bracket, disconnect from site fabrication.
At the front support assembly, remove the two pins,spacer,washers and cotter pins between the wallbox
and front bulkhead plate.
Disconnect the wallbox.
NOTE: Before lowering, the thermoprobe must be pulled away from the wailbox to prevent damage to the
probe and tip.
Carefully lower the thermoprobe onto wooden battens of sufficient thickness to keep all parts of the
equipment well clear of the support structure on which the unit is placed.
Re-installation
Remove any protective coverings from the thermoprobe.
Carry out a detailed inspection of the complete thermoprobe for any signs of damage.
Fit the lifting equipment to the four lifting lugs provided on top of the beam.
Carefully lift the thermoprobe into position.
NOTE: Ensure that the carriage is fully retracted before commencing re-installation.
At the front support assembly, replace the pins, spacer, washer and cotter pins which secure the wallbox
to front bulkhead plate.
At the rear support bracket, re-connect the rear support assembly to the site mounting fabrication.
Reconnect the electrical cables.
Disconnect and remove all lifting equipment.
Re-connect the power supply, and complete the post-maintenance checks.
Check all wiring for continuity and make certain that all electrical connections are tight.
With the boiler operating, run the probe tube forward approximately 300mm to place the thermocouple tip
in a higher gas temperature.
Check that the temperature readout device indicates an increase in temperature.
If no change in temperature is indicated, disconnect the read-out device and monitor the thermocouple
signal with a suitable test instrument to ensure that the read-out device is operating correctly
NOTE
An alternative method of testing is to turn on the aspirating air, if fitted, with the probe tube fully retracted.
If the thermocouple is operating correctly, the temperature read-out device should indicate a decrease in
temperature
Thermoprobe Removal
Retract the probe to the rear limit switch and Isolate the power supply to the main Control Box.
Warning:
It is essential to keep the cooling air supply ‘ON’ to cool the probe tube until it is retracted.
Before removal of the probe, the normal stop block at the end of the rack, on each side of the beam, must
be removed. Do NOT remove the rear stop block. Remove the two hexagonal bolt and washer assemblys
on each block to allow the carriage and thermoprobe assembly to be retracted.
Rack
Manual Operation
Turn the extended shaft on the gearbox with a ratchet wrench fitted to the winder adaptor. In a right or left
hand blower, rotate the socket in a counter clockwise direction to reverse the carriage towards the
normally fully-retracted position.
Under no circumstances should an impact driver be used on the adapter.
Remove the four terminal box cover plate screws and disconnect the thermocouple wires from the
terminal box mounted to the carriage assembly. Disconnect the tails of the thermocouple from the terminal
box. Remove the cable and packing gland.
Thermocouple Disconnection
Probe Tube
Manifold Terminal Box
Thermocouple Wires
Thermocouple Manifold
Tie Bar
Cable &
Packing Gland
Disconnect the air hoses from the elbow connection leading from the thermoprobe manifold.
Position support blocks at the probe tube near the carriage and at the front support bracket; rest the
blocks on the beam flange. Remove the four hexagonal screws and lockwashers which secure the
manifold to the carriage and rest the probe on the tie bars. Ensure that the probe tube does not drop and
damage the manifold.
Manifold Mounting
Screws
Air Inlet
Probe Tip
Shield
Packing
Follower
Sealant
Thermocouple
Thermocouple
Probe Tube
Thermocouple
Tip Shield
Thermocouple
Tip Shield
Carriage
Fabrication
Probe
Tube
Terminal Box
Packing Gland
Manifold Mounting Bolts
Manifold
Support Roller
Washer
Wallbox / Wallsleeve
Mounted to This
Face
Probe Tube
Seal Plate
Split Pin
Wallbox Renewal:
Remove the weld between the wallbox and the wall sleeve.
Position and weld a replacement wallbox to the wall sleeve.
Replace the seal plate, washers, springs, and nuts.
Re-install the thermoprobe in the reverse order to that given for dismantling.
Bearings
Washer
Set Screw Hex Bolts/Washers
Roller Bracket Support Lug
Assembly
NOTE
It is recommended that ball bearings and bearing seals be renewed. Where doubt exists as to
serviceability, new items should be fitted.
Fixing Screws
Roller
Cable Gland
Limit Switch
Limit Switch Bracket Assembly
Adjusting
Screw
Adjustment Procedure
Check that the contact roller engages correctly with the carriage. The angular position of the roller crank
can be altered by loosening the adjustment screw.
The limit switch position can also be adjusted by slackening the fixing screws on the mounting rail or limit
switch plate and sliding the whole assembly in the direction of the adjustment required.
Re-tighten after adjustment.
Operate the thermoprobe manually to check that the limit switches operate correctly when tripped by the
trip plate assembly.
Turn on the blowing medium supply.
Reconnect the power supply and test run the thermoprobe.
Note:
The first and second limit switches are used to set the fully inserted and fully retracted positions of the
thermoprobe.
A third limit swith is used when cooling air is used. A signal from this limit switch will send a signal to the
control system as it is tripped during insertion into the boiler. The transmitted signal will trip the cooling air
input valve allowing the probe to be cooled as it is in the boiler.Refer to Electric Control Assembly Drawing
at the end of the Instruction Manual.
14
12
8 10
13
3
1 11
19 9
4-5
21
1
6
15
#Item 18 (Pop Rivets) are not shown on scheme but are used to mount the Nameplate – Item 17.
11
Motor 21-23
1 24
25
20-21-22
2
10
9 25
3 5
26
7
18-19
6
16 4
13 12 14
15
8 8
17
13
9
7
20-21-22 2
14 14
13
7
17
8
9 15 6
2
5
1
4
3
3
3
1-4-7 8 2
6 5
Roller Assembly (Front Support) – Parts – 394347-4035 – (Sealed for Life Bearings)
Item Description Qty Part Number
1 Roller – 3 ½” Lance 1 319546-1128
2 Ball Bearing 2 901110-8924
3 Washer 2 901402-0001
4 Roller – 2 3/8” Lance 1 N/A
5 Shaft Roller 1 394056-2121
6 Grease Nipple 1 N/A
7 Roller 5” Guide Tube – (Not Used on TP500-E) 1 N/A
8 Hex Soc. Hd. Screw 1 876009-4416
2-3 34
11-12
5-6
30
10 4
8
9
24-29-
31-33
28
13-14-15
7
2-11
21-22
19
28
32
2 LIMIT SWITCH ASSEMBLY
24-29-31-33
17
PROXIMITY SWITCH
ASSEMBLY
16
18
Notes.
Refer to the wiring diagram for details of cables, glands, terminals, proximity switch and front and rear limit
switches. (LSF & LSR)
Cables are routed through the energy chain to the main terminal box mounted on the beam shell. Refer to
the wiring diagram to for connections.
The proximity switch mounting bracket is attached using two of the gearbox mounting foot screws, The
bracket is slotted so that the screws need only be slackened back to allow fitment.
Ensure that the set gap between the proximity switch and the trigger is set correctlt to 0.1 – 1.0mm.
Limit switches are shown with their respective operating levers in the operated position.
Adjust lever angles and trigger positions to achieve the correct switching points.
If possible arrange the carriage start and stop positions to coincide with a scallop on the proximity
switch trigger wheel.
Ensure that all cables are clear of of the trigger wheel and extended worm shaft. The latter is used to
manually move the carriage.
For details not shown in diagram above, refer to section 6.7 for clarification.
20 21-22 19
24-25 24-25 21-22
19 21-22 24-25 19
21
22
24-25
19
21-23
20
26
Triple Switch Quadruple Switch 27
32
28
30
24-29-31-33
Limit Switch Trip Assembly
30
28
24-29-31-33
34
0.1 – 1.0
Switch / Wheel Gap
17-18
16
2-3
1
4
11-12 8
10
13-14-15
10
Tip Shield
Thermoprobe
13
11
12
Guide
Air Outlets
3 (Nozzles)
Hex Plug
7-8-9 6
12
1-10
6
2
6
7-8-9
Non Cooled Thermoprobe Assembly
13
6
4 5
7
1 22
10
9
20 19
8
3
4 21
13-14-15
16-17
12
19
16-18
13-14-15
2
4 5
3 7
2
8
Note. Run one nut up to contact spring. Tighten the nut by two flats.
Fit the second nut and lock against the first.
If applicable, the seal plate machined face should be fitted towards the flange.
3
2
4
6 5
Item/Page Number refer to the page within this manual that the component is depicted.
Contact With Live Parts: For any maintenance, in order to ensure that it is not possible to contact live
parts inside the terminal box or control panel, isolate the terminal box or control panel before accessing
any electrical components. Electrical work should only be done by skilled and professionally competent
employees.
Contact With Live Parts: (Fault Condition): Damage to any electrical cable could cause equipment to
become ”Live”. Ensure that equipment is earthed. Each sootblower and panel has an earthing provision.
Loss of Power: In the event of an unexpected power loss,the thermoprobe may be stopped within the
boiler. It is important, if this situation arises, that the probe assembly is returned to the rear stop position
manually to prevent damage to the lance or boiler tubes. Refer to section 2.4 of the instruction manual for
information on manual retraction of the lance.
Restoration of Power: Thermoprobe may start without warning as they are remotely controlled.
This should not cause additional hazard as long as Thermoprobe guards remain in place. Prior to guard
removal for any reason, electrical power supply must be isolated.
Unexpected Start: The sootblower may be started by a remote control system. To avoid crushing or
other injury, guards must be fitted at all times.
Stopping & Isolation: To comply with relevant directives and legislation DPSL supply thermoprobes with
guards which, as per our risk assessments, negate the need for Stop, Emergency Stop or Local Isolation
on the sootblower.
DPSL consider that each thermoprobe control system should include system stopping facilities as
required to bring the equipment to a safe condition in a safe manner.
Stopping an operating thermoprobe (or isolating which would cause the sootblower to stop) is not
recommended as the thermoprobe would then remain within the boiler which could cause consequential
damage to the probe assembly.
Control Systems in our supply are therefore normally provided with a System Shutdown facility which
typically operate as follows:-
Burns Due to Contact with Hot Parts: Contact with Wallbox, thermoprobe assy could cause burns. Contact
with these components is prevented by the use of guards. Do not make contact with these parts unless
power is isolated and correct protective clothing and gloves are worn.
Burns Due to Contact with pipework and Wallbox: Supply pipework should be insulated where possible to
prevent burns from contact. Limited access to wallbox during use should reduce burn risk but operators
must be made aware of hazard if they are required to work in close proximity for maintenance reasons.
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22 2 841402-0001 Cable Gland, M20, Cable 4-7mm O/D, Nylon, Black, with nitrile sealing washer and locknut for encoder & T/C cable
7 8 9 BK WH WH G R
Dual TC A ncillaries
Type 'K' 23 * Cooling Medium Valve Assy
24 * Pressure Switch (for Cooling Medium)
7 8 9 CAUTION 25 10m 841404-0014 Cable, HiTemp flexible, 3x1.5mm core (2+E) 8mm OD, white outer sheath sleeve cores red
* ISOLATE ELSEWHERE BEFORE Enclosure
ACCESSING ANY TERMINALS 26 # 1 N1183612-C025 Enclosure & Fittings Assy, 600Hx800Wx250D, Sheet Steel 2mm thick, IP65, RAL7032
* UNIT MAY START 27 # 6 848300-9751 Terminal, TS35, WDU6, (800V/57A max), 0.5 to 10mm2 conductor. Weidmuller WDU6
UNEXPECTEDLY 28 # 2 848300-9752 TL Partition, TS35, WDU10, for WDU2.5, 4 & 10
29 # 2 848300-9844 Terminal, Earth, Power Circuit, TS35, WPE6 Weidmuller WPE6
30 # 2 848300-9080 Support Bracket for ADP, Polyamide 6.6
31 # 0.1m 848300-9079 Cover, Transparent
A B B B B B C C 32 # 14 848300-9755 TL End Bracket, TS35, EW35, for WDU2.5, 4 & 10
C 91 58 92 93 90 33 # 37 848300-9768 Terminal, TS35, WDU4 (750V/35A) Weidmuller WDU4 C
d=20.5 34 # 10 848300-9754 TL End Plate, TS35, for WDU2.5, 4 & 10
d=25.4
35 # 1 848300-9783 TL Cross Connector, 2 WAY for WDU 4, WQV 4/2
36 # 7 848300-9779 Terminal, Earth, Control Circuit, TS35, WPE4
Incoming 37 # 17 848300-9967 Terminal, double deck, 2-way, TS35 Rail, type WDK 4N Weidmuller WDK4N
Mot LSR LSF CMS CMV PS Pos Temp Supply Interconnecting Cables to 38 # 4 848300-9963 Terminal, double deck, 4-way, TS35 Rail, type WDK 4NV
39 # 7 848300-9885 End Plate, for double deck WDK..N type terminal
Cable entries at rear of panel from
PDP B
PDP B 40
41
#
#
2
1
848300-9984
848301-0004
TL cross Connector, 2 WAY for 4N
Earthing Bolt Kit, M10, SS304 - supplied loose for panel earth
42 # 0.7 849571-9243 Cable sleeving, Heat shrink 2.4mm², Red For sol cable cores
43 # 0.7 849571-9249 Cable sleeving, Heat shrink 4.8mm², Yellow For motor cable cores
44 # 0.7 849571-9287 Cable sleeving, Heat shrink 4.8mm², Red For motor cable cores
45 # 0.7 849571-9288 Cable sleeving, Heat shrink 4.8mm², Blue For motor cable cores
A = 4, 5, 6 46 # 10m 849585-9293 Wire, 1.0mm, 500V, Halogen Free, IEC 60332.1/3, 125oC, Blue
47 # 60m 849585-9295 Wire, 1.0mm, 500V, Halogen Free, IEC 60332.1/3, 125oC, Red
B = 11, 12, 13 800 48 # 10m 849585-9324 Wire, 2.5mm, 750V, LSOH, IEC 60332.1/3, 125oC, Red
49 # 10m 849585-9325 Wire, 2.5mm, 750V, LSOH, IEC 60332.1/3, 125oC, Yellow
D C = 9, 10, 11, 13 50 # 10m 849585-9326 Wire, 2.5mm, 750V, LSOH, IEC 60332.1/3, 125oC, Blue D
51 # 10m 849585-9309 Wire, 2.5mm, 750V, LSOH, IEC 60332.1/3, 125oC, G/Y
52 # 1 907506-8927 Label, "Warning - Thermoprobe", English fit before shipping
53 # 1 907506-8954 Label, "Warning - Thermoprobe", Vietnamese fit before shipping
54 # 1 907506-8904 Label, WARNING, Main MCB Isol. Switch.
55 # 4 847313-9208 VCI Foam Square, corrosion protection for motor & sootblower terminal boxes
56 # 2 866507-8902 Self tap screw, No.4x8mm A2, SS
57 # 1 N11836-LB02 Nameplate, stainless steel, black engraved/lasered lettering, engraved as shown
58 # 1 * Entry, 25.4mm dia clearance hole
Starter Kit
59 # 1 842800-9385 Door Coupling Mech. for Rockwell MCB 140M-D, R/ Y Handle
60 # 1 842800-9318 MCB/TOL, FLC 1.6 - 2.5A
61 # 1 842800-9386 Extension Shaft, for Rockwell Door Coupling Mech
Enclosure 62 # 1 842800-9398 Aux. Contacts, 2 NO , for Rockwell 140M MCB/TOL
63 # 1 842800-9482 MCB, 2-pole, 4A, 'C' trip
600H x 800W x 250D 64 # 2 846400-9344 Contactor, 110V 50/60Hz, 3-Main pole, 1-NO
Single hinged door, 65 # 1 846400-9345 Locking Mech. for 100-C ContactorS (REV. MC)
E
Frame & Doors - 2mm thick 66 # 1 846400-9413 Electrical interlock bus bar for 100-C Contactors E
Mounting Plate - 2mm thick 67 # 2 846400-9430 Aux contact, 2-NO + 2-NC, front mounting for 100C contactors
Material - Carbon Steel 68 # 1 846431-9304 EOL, 1.0-5.0A, 1 NO & 1NC Aux Contact, AUTO/MAN Reset
600
69 # 1 846431-9302 DIN Rail/Panel Adapter for 846431-9303,4 type EOL
Ingress - IP65 minimum 70 # 1 846400-9329 Relay Base, 4-CO, DIN MT, 30mm
Paint spec - RAL 7032 (textured) 71 # 1 846400-9325 Relay, Plugin, 24VDC, 4-CO, c/w LED
72 # 8 846400-9433 Base, 8-pin, 16mm wide, DIN rail mount, c/w clip, black
73 # 8 846400-9435 Relay, PlugIN 16mm, 24VDC, 2-CO, LED
74 # 1 846421-9282 Multi Function Time Delay Relay 24VDC/230VAC supply SPDT
75 # 1 847313-9134 Rail, TS35 x 2m LENGTH, Unslotted, Top HAT DEEP
76 # 1 847360-9393 Pushbutton, White, Illuminated, Signum 3SB3 insert
77 # 1 847360-9391 Pushbutton, Red, Illuminated, Signum 3SB3 stop
78 # 1 847360-9392 Pushbutton, Illuminated, Green, Signum 3SB3 reverse
79 # 2 847360-9358 Contact Block, 1-NO
80 # 1 847360-9360 Contact Block, 1-NO + 1-NC
81 # 1 847360-9361 Contact Block, 2-NO
82 # 2 847360-9362 Contact Block, 2-NC
83 # 1 847360-9385 Selector switch, 2-position, non-illuminated, black, including holder, Signum 3SB3
F F
84 # 5 847360-9400 Nameplate Holder
250 85 # 1 847360-9398 Indicator, White, Signum 3SB3 ready
86 # 1 847360-9364 Lampholder, LED, Red, 24VDC, Signum 3SB3
Removable Gland Plate 87 # 1 847360-9365 Lampholder, LED, Green, 24VDC, Signum 3SB4
88 # 2 847360-9367 Lampholder, LED, White, 24VDC, Signum 3SB5
89 # 1 N11836-LB01 Label set for PB & Lamp, 5 labels total, engraved as shown "LOC/REM", "Ready", "Insert", "Retract", "Stop"
Contract Specific Requirements
90 # 3 * Entry, 36mm dia. clearance hole
91 # 1 849517-8963 Cable Gland, 25mm, Nickel Plated Brass, for customer cable (non-armoured)
92 # 1 * Entry, 28mm dia. clearance hole
General Arrangement 93 # 1 * Entry, 50mm dia. clearance hole
=> N11836-618 Electrical Parts Assembly, TP500-E
N11836-618TB Starter Assy, populated, TP500-E assy of # parts only
WARNING
G Do not operate locally unless permitted to do so. G
Do not carry out maintenance until blowing supply is locked OFF.
Do not carry out maintenance until all voltage supplies are locked OFF
Notes
1 - Unit is shown in rest position with LSR actuated.
2 - Internal wiring is by DPSL, interconnecting cable and glands by LMB. TP500-E
3 - Any voltages shown are actual volts carried by the cable, they do not show size or rating of cables.
4 - A cable loop should be arranged to allow for boiler expansion.
5 - Installer to ensure incoming earth is connected to PE terminal as required by local regulations.
TP500-E THERMOPROBE WIRING DRAWING
H H
THIS DRAWING AND THE INFORMATION IT CONTAINS Rev DATE REVISION BY CH Rev DATE REVISION BY CH Rev DATE REVISION BY CH Rev DATE REVISION BY CH DRAWING STANDARDS BASED ON
DIMENSIONS ARE IN MILLIMETRES UNLESS OTHERWISE STATED
HAVE BEEN FURNISHED FOR USE BY YOUR OWN A 09 Mar 2017 First Issue P.T. R.A. BS 308
ORGANISATION ONLY AND FOR PURPOSES
CONSISTENT WITH THE TRANSACTION BETWEEN B 29 Mar 2017 Updated for client comments (Entry holes) GE PT DRAWN BY gerwin DATE: 07 Jul 2017 SCALE: N.T.S A1
YOUR ORGANISATION AND DIAMOND POWER. NO C 06 June 2017 Updated for client comments (M25 gland -> M20, Entry hole 36mm Dia.) GE RA
COPIES OF OR DATA FROM THIS DRAWING SHALL BE SHEET 1 OF 3 Rev
FURNISHED TO ANY THIRD PARTY WITHOUT THE D 29 June 2017 Updated entry details as per DHI comments GE GE CHECKED BY R.Allan
WRITTEN AGREEMENT OF DIAMOND POWER
SPECIALTY LTD. DUMBARTON SCOTLAND.
E 07 July 2017 Item 93 added for (DHI field cabling entry requirement for 19-core cable) GE RA
APPROVED BY P.Thompson N11836-4-618 E
1 2 3 4 5 6 7 8 9 10 11 12
S:\controls\ALL\All_drawings\drgs solidedge & cimcad\N 11800-N11899\N11836\N11836-4-618-2E.dft
1 2 3 4 5 6 7 8 9 10 11 12
THIRD ANGLE PROJECTION Door interlocked, Schematic of Power & Control Circuit Electronic Overload Notes
open in 'O' Range - 1.0 - 5.0A
A MCB/TOL A
position only. Set - 1.5A
Range - 1.6 - 2.5A
O I Set - 1.8A for TP
Auto Reset
Local/Remote Selector = switch must be selected to REM to enable remote Insert and Stop
Manual Reset FA1.1 commands. Remote reverse is enabled at all times to allow the DCS operator to retract the TP.
400V 3ph 50Hz
L1
QM1.1 L4 KM1.1 L7 U
Incoming
Supply
2 1 1 2
M
L2 L5 1 2 L8 V
L3 4 2
L6 3 4 L9 3 4 W Remote Insert = remote Insert momentary pulse starts the TP forward.
6 3 5 6 5 6 The TP then runs forward to the front position and stops.
PE
PE When the LSF signal advises that the TP is at the front position the TP can be left for a short
KM1.2 period to read the temperature then the TP should be retracted by Local or Remote Reverse
PE
FA1.1 trips instantaneously to stop the TP on motor overload. command.
1 2
If the motor overload persists the MCB/TOL trips to cut the supply
MCB 3 4 and stop the motor. The TP should not be left at the front position for a continued period (typically 30s max)
Turn MCB/TOL handle to O then to 1 to reset.
B QF1.1 5 6
If necessary retract the thermoprobe by hand.
B
2x4A
Remote Reverse = remote Reverse momentary pulse reverses the TP.
24VDC Supply
Char C
(From PLCP)
TO SHEET 3
Incoming
24V 13 14 J1A 1 2 J1 J1
0V 21 22 J2A 3 4 J2 J2
Remote Stop = stops the TP, it can then be re-started in either direction by Insert or Reverse.
PE
Do not stop the TP for a continued period (typically 30s max).
Note that if the TP is stopped by remote Stop then Faults FA1.1 overload, High Temp, or Low
PE Press will override the Rem Stop to retract the TP.
'STOP'
J3 Stop
LSR = TP rear limit switch tripped (indicates that the TP at rest)
J13 J26
LSF = TP front limit switch tripped (indicates that the TP fully inserted)
KA2.3
C C
J4 KA1.3 KA2.3 TP Ready = ON signal indicates Ready, the TP MCB/TOL is ON, and all voltages & alarms are
healthy.
'LOC'
= OFF indicates combined TP Fault.
TO SHEET 3
J17
'REM' KM1.1 KA2.1 0 = HIGH On Faults Electronic Overload FA1.1 trip, High Temp or Low Pressure if the TP is operating it will
J5 J14 TEMP (N/C
KA1.4 contact of J25 be retracted automatically.
'INSERT' J22
temp
indicator)
KM1.2 KA1.3 KA2.2 KA1.1 KM1.1 KM1.2 Caution
J6
J15
If the TP Ready/Fault signal goes OFF the operator should check the TP immediately to ensure it
'RETRACT' KT1 = TIMER FA1.1 is at rest and retract by hand if necessary. Extended periods in the boiler with or without cooling
J10 J18 J20 (0.1s-120h Range) J23
D
J7 Set at 5s air can damage the probe tube. D
J12 KM1.1 KA1.2 DELAY ON
KA2.2 KM1.2 J19
ENERGISE KT1
J11 J16
J8 J21 J24
KM1.1 KA1.0 KM1.2 KA1.1 KA1.2 KT1 KA1.3 KA1.4
KA1.3 MI TP-500E WIRING
J9
POWER
Insert Retract 400VAC 3ph 50Hz 2.5mm², RED, YELLOW, BLUE
COUNTER RESET Ready
- see SHEET 3
J33 J34 J31 J32 J35 J36
TP EARTH 2.5mm² GREEN/YELLOW
Starter X3 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34
CONTROL
E
TP500-E 24VDC 1.5mm², BLUE E
1 2
14 13 14 13 14 13
J31 J32 J33 J34 J35 J36 J38 J40 J42 J44 J46 J71 J73 J75
THIRD ANGLE PROJECTION Schematic of Position & Temperature Circuit Internal Layout
A A
SETPOINTS
Tmax without cooling air = approx 593oC. X1 X3 X4 X5
Tmax with cooling air = approx 816oC. J9 J34 J31 J12 J17 J19 J19 J36 J2 SCR UP DN TTX2 TTX2
SCR SCR TTX1 TTX1
COUNTER
UP/DOWN
J1
TX1+ GREEN Set Point for High Temp Retract = approx 800oC J33 J10 J1 J32 J12 J2 J35 J21
+ - + -
DUAL
TX1- WHITE
THERMOCOUPLE
Low Pressure = 22 psig (2.53 barg) 2 4 6 8 10 12 14 16 18 20 22 24 26 28 30 32 34
TX2+ GREEN POSITION - see TP Ins Manual. U V W PE 1 3 5 7 PE 9 11 13 15 PE 17 19 21 23 PE 25 PE 27 29 31 33 PE 1 2 3 4 5 1 2 3 4 5 6
TX2- WHITE UP/DOWN
J1 BROWN
COUNTER
POSITION ENCODER - UP/DN MAY to PE
UP WHITE
BE SWAPPED TO CORRECT UP/DOWN Stud
DN BLACK
B COUNT IF REQUIRED. B
J2 BLUE LSF LSR CMS CMV PS
Prox Sw Thermocouple
SCRN
Contact opens
JUNCTION BOX on high temperature.
POSITION INDICATOR TEMPERATURE INDICATOR
0 0.0 0 J1 21 22 23 24 25 26
0 0.0 0 QF KA KA KA KA KA KA KA KA
21 22 23 24 25 26 QM1.1 KM1.1 KM1.2 FA1.1 1.1 KT1 1.0 1.1 1.2 1.3 1.4 2.1 2.2 2.3
41 42 43 44 45 46 11 12 31 32 J25 41 42 43 44 45 46 11 12 31 32
J1 J1
C CABLE CHAIN
P2 P1 J2 T1 T2 J2 C
PULSE
UP/DOWN
COUNTER
9+
J1
X0 X2 X6 X7 X8
10 -
J2 P1 P2 SCR T1 T2 SCR
KA1.0
RESET
J1 J27 4-20mA
FROM SHEET 2
11
SIGNAL L1 L2 L3 PE 24V 0V SPR 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 1 2 3 4 5 6 PE 1 2 3 4 5 6
PE
J1 UP UP
1 X2 STUD
D 4 pnp D
CHANNEL 3
J2 X1
TX2+
TX1+
TX2-
TX1-
SCR
SCR
SCR
DN DOWN SCRN
DN
UP
J1
J2
SCR
P1
P2
T1
T2
E E
ALL FIELD CABLES BY OTHERS
J1 & J2 TEMPERATURE
NB: All DCS Remote Control, Positional & Temperature Feedback for
POSITION
Marshalling SIGNAL SIGNAL TP1 (P1HBK10CT001 for Unit 1 / P2HBK10CT001 for Unit 2)
4-20 mA 4-20mA and TP2 (P1HBK10CT002 for Unit 1 / P2HBK10CT002 for Unit 2)
Via Interface with PDP B
( P1HCB20GW002 for Unit 1 / P2HCB20GW002 for Unit 2)
F F
Pulse Up/Down Counter Settings Position Indicator Settings Temperature Indicator Settings
Type - PR2281 IN - current IN - temp
Input - PNP 24VDC Range - 4-20mA TYPE - TC
PUP - HLd DEC.P - 11.11 TCTY - TC.K
RES - 0.00 DILO - 0 DEC.P - 111.1
PRE - 001 DIHI - 9.07 UNIT - oC
UHI - 027 A.OUT - 4-20 REL 1 - SET
ULO - 210 0.ERR - 3.5mA SETP - 815
dHI - 027 RESP - 0.4 ACT1 - INCR
dLO - 210 EPAS - no HYS1 - 1
OL - 4.00 ERR1 - ACTI
OH - 20.0 ON.DE - 10
G U1 - 002 OF.DE - 10 G
OR - off REL2 - OFF
FUn - 003 AOUT - 4-20mA
EFS - dFS O.LO - 0.0
FLt - HI
PAS - 040
O.HI - 1000
O.ERR - 3.5mA
TP500-E
RESP - 1.0
E.PAS - NO
DETAIL B
1:1.5
6 10 1 2
C C
C
B
SECTION A-A
1:2 6
3
D D
DETAIL C A
1:1.5
13 7 9 8 4 6 9 7 1:2
11 11 LH ORENTATION OF ELBOWS
E E
11
12
12 12
F F
G G
1:2 1:2
PROBE TUBE & MANIFOLD ASSY - AIR COOLED
(DYE PEN TESTING)
H H
THIS DRAWING AND THE INFORMATION IT CONTAINS Rev DATE REVISION BY CH Rev DATE REVISION BY CH Rev DATE REVISION BY CH Rev DATE REVISION BY CH DRAWING STANDARDS BASED ON
DIMENSIONS ARE IN MILLIMETRES UNLESS OTHERWISE STATED
HAVE BEEN FURNISHED FOR USE BY YOUR OWN A 10 Jul 2017 First Issue G.S. J.B. BS 308
ORGANISATION ONLY AND FOR PURPOSES
CONSISTENT WITH THE TRANSACTION BETWEEN DRAWN BY G.Sharp DATE: 03 Jul 2017 SCALE: N.T.S A1
YOUR ORGANISATION AND DIAMOND POWER. NO
COPIES OF OR DATA FROM THIS DRAWING SHALL BE SHEET 1 OF 1 Rev
FURNISHED TO ANY THIRD PARTY WITHOUT THE CHECKED BY J.Bennett
WRITTEN AGREEMENT OF DIAMOND POWER
SPECIALTY LTD. DUMBARTON SCOTLAND. APPROVED BY A.Wylie N1183614-C023 A
1 2 3 4 5 6 7 8 9 10 11 12
NUMBER REV
FRAME
Type S.C.I.M.
Size 80 (Total length including shaft ‘L’ = 276 see Note)
Mounting IM3001 (B5) (Flange, Shaft Horizontal, No Feet)
Enclosure T.E.F.C. (IC 411) IP55
Frame Material * Cast Iron
Paint spec Makers standard
Colour Makers standard
Humidity suitable for 95% relative humidity
Drain No drain holes (if fitted plug to IP55)
Nameplate S\S (on RHS when facing DE) VIEW FACING DE
ELECTRICAL
Output 0.55kW (50Hz); 0.63kW (60Hz)
Power supply 380 to 420V 3ph 50Hz / 440 to 480V 3ph 60Hz - Star supplied STAR connect
220 to 240V 3ph 50Hz / 250 to 280V 3ph 60Hz - Delta
Supply variation Voltage as shown above 5%. (with B temp rise)
In addition voltage 10% variation (with F temp. rise).
Frequency variation 2%
Insulation Class F with class B temp. rise
PERFORMANCE
Speed 1500 rpm @ 50Hz / 1800 @ 60Hz (4 pole) (actual 1410 / 1710)
Rating S1 @ 40oC & 1000 masl
S2 15min @ 60 oC (@ nominal voltage range) (with F temp. rise)
S2 15min @ 2000masl (@ nominal voltage range) (with F temp. rise)
Rated current 1.34 A @ 400V 50Hz / 1.44 @ 460V 60Hz
Starting current 660% (Direct on line)
Rated / Starting torque 3.73 Nm / 250%
Power factor .83/ .77 @ 1 / .75 Full Load
Efficiency IE2
SPECIFICATIONS
Specs IEC 60034
Type Test cert required
ECDec=WEG Equipamentos Elétricos SA EC Declaration
of Conformity 02-2010
REV DESCRIPTION DATE ISS'D BY APP'D