D5-E MKII Page 1 of 1 00

INSTALLATION, COVER PAGE

COMMISSIONING, OPERATION & 23 March 2009 Revision Number 1
MAINTENANCE MANUAL Document I.D. D5EMKII.00.Manual Cover Page

D-5E MKII SOOTBLOWER

Installation, Commissioning, Operation, & Maintenance

Manual

For

Tecno Controles Y Equipos

Altos Hornos De Mexico

Clyde Bergemann, Inc. Sales Order No.: Q-10351201

Customer Purchase Order No.: TCE-1534

Date: October 25, 2012

The information and instructions contained in this manual are general by design. Details on specific equipment manufactured for this
project are contained in drawings and information located at the back of this manual immediately following Section H2

Reviewed By Date
Approved By Date
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INSTALLATION, TABLE OF CONTENTS
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TABLE OF CONTENTS

A. GENERAL DESCRIPTION
A1. Basic Description
A2. Major Components
A2.1 Elements
A2.2 Bearings and Hangers
A2.3 Gearbox, Pinion and Bullgear
A2.4 DVT-FS Head Valve and Operating Mechanism

B. INSTALLATION
B1. On-Site Supervision
B2. Wall Sleeves
B3. Element
B4. Soot Blower Head
B5. Piping
B6. Wiring
B7. Setting the Element Sweep
B8. Limit Switch Adjustment

C. COMMISSIONING
C1. Test Checklist
 Blowdown (Piping) Recommendation (see Appendix A)
C2. Precautions Before Blower Test
C3. Element Rotation Test
C4. Check Motor Starter Contact and Limit Switch Actuation
C5. Local Operation Test/Check Mechanical Operation of Limit Switch
C6. Check Remote Controls
C7. Check DVT-FS Head Valve Actuation
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D. OPERATION
D1. General Note
D2. Powered Operation
D3. Setting Blowing Pressures
D4. Determining Operating Frequency
D5. Suggested Blowing Procedure

E. TROUBLESHOOTING

F1. ROUTINE MAINTENANCE

F1. Maintenance Schedule
F2. Visual Inspection/Establishing a Maintenance Schedule
F3. Lubrication & Chart
F4. Cleanliness
F5. Packing
F6. Preventive Maintenance Checklist
F7. Inspection

F2. LUBRICANT CHART

G. REPAIRS
G1. Precautions
G2. Emergency Service – Motor Failure
G3. Recommended Procedure for Installation of Packing
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H. EQUIPMENT SPECIFICS
H1. Illustrations
1.1 Typical D-5E MKII Rotary Soot Blower
1.3 Welded Bearings
1.4 Compression Bearings and Crown Bearing with Straps
2.1 Typical Pressurized Wall sleeve
Positive Pressure Wall Sleeve
Negative/Balanced Draft Wall Sleeve

H2. Spare Parts List

STANDARD MODEL DRAWING(S)

PROJECT SPECIFIC DATA

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A1. BASIC DESCRIPTION

The Clyde Bergemann Model D-5E MKII Rotary Soot Blower is an electric motor operated soot
blower designed for industrial and utility boiler applications. The function of the soot blower is to
remove deposits that form on the boiler tube surfaces. Reference Figure 1.1, Section H.1
The multi-nozzle soot blower element (Item 4) is permanently located within the tube bank to be
cleaned. The element can extend across the entire tube bank, or on larger boilers where rotary
soot blowers are used on both sides of the boiler, halfway across.
The specially designed nozzles are positioned along the element so that one nozzle is located in
each tube lane. The nozzles may be located on one or both sides of the element.
The element is attached to the soot blower mechanism by means of an element flange. (Item 5)
The rotary soot blower is mounted on the external casing of the boiler. The combination gear
drive rotates the element as blowing medium, steam or compressed air, passes from the cam-
actuated DVT-FS head (Item 8) through the element and exits the nozzles. The thrust created by
the nozzles removes the deposits on the boiler tubes.
The gearbox/electric motor (Item 10) automatically shuts off when the full 360˚ blowing sweep of
the element is completed.
Although the nozzle always rotates a full 360˚, the actual blowing arc (or sweep) can be limited to
any portion of the 360˚ sweep in 30˚ increments by simple adjustment of the head-opening cams.
(Item 3) Special cams for non-standard counter-clockwise rotation are also available.
Head blowing pressure can be adjusted externally by rotation of the valve operator on the stem.
(Item 2). Valve stroke adjustment is made by means of an adjustment screw (Item 1).
To prevent infiltration of corrosive furnace gases through the element to the head valve, a
scavenging air check valve (Item 9) is furnished as standard on all rotary soot blowers. For
pressurized furnaces, a purging air line from a source of higher pressure than furnace pressure is
connected to the scavenging air valve mounted on the DVT-FS head.
Refer to Section D for specific instructions in setting the element sweep, head blowing pressures
and valve stroke.
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A2.1. ELEMENTS
The element is that part of the rotary soot blower equipment that distributes the blowing medium
inside the boiler for the purpose of cleaning the tubes. Elements are specially prepared tubes
containing nozzles for the distribution of steam. Refer to Figure 1.2, Section H.1.
Each Clyde Bergemann soot blower element is engineered and tailored for its specific job based
on the type of boiler on which it is to be installed, the temperatures it must withstand, the
pressures used for blowing, and the job of cleaning that must be performed.
Elements are made on 1-1/2” or 2” pipe. Some elements are provided with couplings for ease of
installation. Couplings eliminate the need to remove the heavy element for the purpose of cutting
to proper length. When couplings are used, it is necessary only to cut the piece from the coupling
to the soot blower head. The coupling is placed inside the wall away from the high temperature.
Most elements are furnished in one piece; however, they can be made in two or more sections,
with couplings or with welded ends.
a. HYVULOY
This chrome alloy affords high heat resistance and retainment of its refined grain structure
and ductility for many years. It is also immune to chemical reaction to high-temperature
gases and is extremely resistant to permanent change in shape.
Hyvuloy elements are suitable for use in flue gas temperatures up to 1800˚ F.

b. HR-160
This alloy is for use with sustained flue gas temperatures up to 2000˚ F and in highly
corrosive atmospheres.

c. VULCROM
Made of heavy steel pipe protected by a surface coating of chromium, this material may
be used in temperatures ranging from 900˚ F to 1500˚ F.

d. PLAIN STEEL
Plain steel elements may be used in low temperature applications where flow gas
temperatures do not exceed 900˚ F.
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e. COMPOSITE
When a single element passes through zones of different temperatures, a continuous
element made up of sections of different materials, with the correct material used in each
zone, may be employed.
The sections of composite elements may be welded or connected with couplings.
Each element has a single or multiple row of accurately machined nozzles welded
securely in place, making a permanently fused, one-piece construction.
The size and location of the element nozzles depend on the spacing of the tubes and the
cleaning to be done. The nozzles may be directed to blow perpendicular to the element or
at any angle, depending upon the tube arrangement.
There are two basic nozzle designs, which can be considered for a given application:
straight bore and venturi.
Straight bore nozzles are employed in densely packed tube banks where deposits are
easily removed. This low energy nozzle provides cleaning by producing localized
turbulence, which excites particulate and causes them to be dislodged.
Venturi nozzles are used when tube lanes permit deeper penetration. This high-energy
nozzle provides a greater depth of cleaning.

2.2 BEARINGS AND HANGERS

The element is usually supported in its entire length by element bearings and hangers, which are
normally fastened to the boiler tubes. Bearing materials, like element materials, are selected
based on the temperature zone in which they are to be installed. Each type of bearing has its
own specific application that is governed by the type of boiler and the method of construction.
As a general rule, steel bearings are used on plain steel elements in low temperature zones and
Hyvuloy bearings are used on Vulcrom elements in mid-temperature zones and on Hyvuloy
elements in high-temperature zones. Alloy HR-160 elements, used in sustained high
temperature, highly corrosive atmospheres, use bearings of the same material.

a. WELDED BEARINGS
The most commonly used bearings, shown in Figure 1.3, Section H.1, are welded. These
bearings are made of plain steel or Hyvuloy. Weld rod of material compatible with the
boiler tube material must be used when installing these bearings.
Crown bearings with straps, shown in Figure 1.4 Section H.1, may be used as an
alternative to welded bearings.
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b. CROWN BEARINGS
Crown bearings may be used where tube spacing or other interference preclude the use
of welded bearings. Made of Hyvuloy or steel, these bearings consist of one bearing, two
clamps, four washers, four bolts and four nuts. Washers are welded to the clamp for ease
of installation. The clamps are effective in maintaining correct bearing position.
c. DISTAL END BEARINGS
The distal end bearing is used to support the distal, or plugged, end of the element. This
type of bearing is most often used on elements spanning short distances where no
intermediate support is required. Distal end bearings are usually welded to the boiler
casing.
NOTE: If exact duplicate bearings are required for maintenance, repair, or replacement, the
position at which the bearings are used and the Clyde Bergemann job number (found on
all application drawings) must be supplied to Clyde Bergemann.

A2.3 GEARBOX, PINION AND BULLGEAR

The gearbox is driven by an electric motor, either 1/8 HP (standard) or 1/4 HP (special
applications) that is mounted directly to the input of the gearbox. The high speed of the electric
motor is lowered through a series of reduction gears to the slow speed output shaft of the
gearbox and coupled directly to the drive pinion. The drive pinion turns the bullgear, which is
attached to the feed tube/element.

A2.4 DVT-FS Head Valve and Operating Mechanism

The model DVT-FS is a mechanically operated, externally adjustable poppet valve. The valve
incorporates a flat main seat for open and shut operation and an adjustable pressure disc
downstream of the main seat for pressure control thus minimizing erosion and steam cutting of
the main seat. The force of an operating cam pushing down on the valve stem opening the valve.
An external spring returns the valve to the shut position. Turning the operator on the valve stem
while the valve is open changes the position of the internal pressure control disc. The main body
of the valve also serves as a mounting place for the gearbox and feed tube.
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B1. ON-SITE SUPERVISION

It is recommended that the customer arrange to have a Clyde Bergemann service engineer on
site to supervise installation and initial start-up of the Clyde Bergemann equipment.
After the blower is installed, and prior to boiler start-up:
a. Inspect the installation of each blower. Check the equipment for damage caused during
installation. Check for missing components, etc.
b. Check the mechanical and electrical installation.
c. Set the element sweep.
d. Test-operate each blower. Check mechanical and electrical operation.
e. When blowing steam is available:
f. Set blowing pressures. Refer to instructions in Section D

B2. WALL SLEEVES

Prior to installing the wall sleeves or the blowers, review the application drawings for specific
details and dimensions. The proper installation of rotary soot blowers is shown on the soot
blower application drawings.
There are two general types of sleeves, those for brick walls and those for steel.
B2.1 Brick Set Wall
Install the sleeve shown on the application drawings. Make sure the sleeve elevation and
vertical location are exactly as shown on the drawings. Usually the back of the sleeve
adapter is installed square and flush with the boiler wall.
Sleeves for brick walls have lugs on the sides to hold them in position. With the sleeve in
place, build up the wall so it completely surrounds the sleeve.
Do not leave open spaces between the refractory and the sleeve.

B2.2 Steel Cased Wall

Install the sleeve as shown on the application drawings. Make sure the sleeve elevation
and vertical location are exactly as shown on the drawings. The correct size hole should
be cut in the casing panel and through the insulation/refractory.
The wall should be built up so that it completely surrounds the sleeve, do not leave open
spaces between the refractory and the sleeve.
With the wall built up and the sleeve and casing panel in place, tack weld the sleeve
adapter (or the sleeve tube if the sleeve adapter is not flush with the casing panel) to the
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casing plate. Generally, 1/2” welds spaced 1” apart on all four sides (or all around the
tube) are sufficient. A continuous weld should be made on all four sides on positive-fired
units.
NOTE: If it is necessary that the blower be installed at an intermediate angle, the entire
sleeve must be positioned at this angle. The position of the blower is shown on the
application drawing.

B3. ELEMENT
After the sleeve is properly installed and the element bearings are in place as shown on the
application drawings, the element should be installed.
Insert the element through the sleeve and bearings. Be sure the element nozzles are in correct
relation to the boiler tubes, as shown on the application drawings. Unless specified otherwise on
the application drawings, the nozzles are centered in the boiler tube spaces.
Place the element in the correct position in the boiler, paying particular attention to the alignment
of the nozzles with the spaces between the boiler tubes. The element end will extend through the
sleeve.
The element must be secured to the gear and extensions assembly of the blower. The
application drawings show the location of the end of the element in relation to the boiler wall. The
end of the element that extends through the sleeve must be cut to length so that, when secured, it
will be the proper location and all nozzles will be properly aligned with the tube spaces. Thread
this end as required. (Refer to the application drawings.)
If the letters “R” (right) and “L” (left) appear on the element, the element must be installed
accordingly. If the element is not marked, installation can be made from either side, whichever is
the most convenient. (An installation is a right-hand installation, if, when standing in front of and
facing the boiler, the operating head and piping are on your right side. If the operating head and
piping are on your left side, the installation is a left-hand installation.)
When the alleyway or aisle space is available, the elements can be inserted directly through the
holes that have been cut in the brickwork or casing. When the boilers are closely set or
positioned close to any other obstruction, couplings should be provided to install the element in
sections. This situation should have been considered in the design of the element.
To connect the element to the blower on a non-pressurized, balance draft unit, place the seal
plate over the end of the element as shown on the application drawings. Place the sleeve cap
spring against the seal plate. Connect the element securely to the element flange, which is
fastened to the soot blower head.
Check all dimensions to be sure the element is correctly positioned and the nozzles are properly
aligned with the tube spaces.
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Pressurized boilers have a different type wall sleeve. (See Figure 2.1, Section H.1.) A stuffing
box and packing are supplied to seal around the element. Care must be taken at assembly to
center and align this stuffing box to prevent binding the element. After installing the stuffing box,
check the position of the element. Couple and secure the element to the blower.
NOTE: The element flange and nipple connection must be steam tight and the set screws
secured. If the element turns in the flange, the blowing arc will be altered and tubes, drums or
baffles endangered by blowing medium impingement.
NOTE: The nozzle position is punch marked or scribed on the element, nipple, and element
flange so the location of the nozzles can be quickly determined from outside the boiler. This mark
may be used for periodic inspection or correction of the blowing sweep and facilitates adjustment.

B4. SOOTBLOWER HEAD

The soot blower head is supported from the sleeve adapter. Attach the head to the sleeve
adapter with the three 5/8” support studs of the head assembly and secure in place with washers
and 5/8” nuts. Torque these bolts to 20 ft/lb.
It is very important that the element rest at the bottom of each tube bearing and that the nozzles
are in the proper location when the head is assembled to the element. The head should not lift
the element up from the bottom of any bearing. The horizontal and vertical locations of the
element in the sleeve should be the same as those on the application drawings.

B5. PIPING
When the piping is erected, great care should be taken to make up the head inlet flange joint
properly. The sootblower head should not support the piping. Proper pipe supports and guides
should be used to prevent piping strain. Refer to the application drawing for allowable forces and
moments for the rotary soot blower.
The piping should be sloped to drain, with sufficient expansion loops to absorb the thermal
expansions expected. Improperly drained piping could cause water hammer during opening of
the soot blower valve, which would lead to soot blower valve or element damage or premature
tube failures.
Make up the companion flange and pipe to align with the mating flange. When the companion
flange is attached to the pipe correctly and the gasket installed, the flanges should match
properly. There should be no strain when securing the flanges. Unless the piping is “cold-
sprung” in the off-line condition to accommodate anticipated expansion when the unit is on line,
the companion flange should not spring apart or to either side when studs and nuts are removed,
nor should the pipe push the head in any direction.
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B6. WIRING
Refer to wiring diagrams for full information on power and control wiring.

B7. SETTING THE ELEMENT SWEEP

The sweep of an element is the angular distance through which it blows. The angle and location
of this sweep is shown on the application drawing.
It is important that the sweep be adjusted as closely as possible to that shown on the soot blower
application drawing. It is not economical to blow steam into any part of the boiler where cleaning
isn’t needed. Damage will occur if nozzles point directly at baffles, walls, drums, or tubes.
The soot blower element rotates in one direction only – usually clockwise. The element must
rotate 360˚ in each operating cycle even through blowing may only taken place over a sweep less
than 360˚.
To establish the desired blowing arc with the 360˚ rotation of the blower, cams are attached to the
main driving gear to form a solid ring to hold the valve open for that part of the 360˚ rotation
where blowing is required. These rings of cam segments are composed of an opening cam, a
varying number of spacer cams, and a closing cam.
A unit that blows 360˚ is equipped with one opening cam, four spacer cams and one closing cam.
Each of these segments covers 60˚ of the blowing arc (60˚ x 6 = 360˚). The blowing arc may be
reduced 60˚ by eliminating one of the spacer cams (60˚ x 5 = 300˚). The spacer cams can be cut
to reduce the blowing arc in increments of less than 60˚. Spacer cams in 30˚ increments are also
available from the factory.
The sweep should be set as follows:
a. Determine the location of the nozzles. Each element is prick-punched for several inches
between the soot blower and the sleeve plate (or stuffing box). These punch marks are in
line with the nozzles.
b. Remove all cams from the driving gear.
c. Rotate the element until the nozzles are positioned at the start of the blowing sweep.
Install the opening cam so that it contacts the roller cam follower at this point.
d. Continue rotating the element, adding the required number of spacer cams and the
closing cam. If the blowing arc must be reduced in increments of less than 60˚, the
spacer cam may be cut. If a cam is cut, care must be used to maintain correctly spaced
holes so that the cam will mount properly on the main gear.
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B8. LIMIT SWITCH ADJUSTMENT

The limit switch is factory set but should be field checked after the soot blower has been installed,
the element coupling made up, and the blowing arc established.
The switch is normally timed to the head-opening cams on the main driving (bull) gear. If the
blowing arc is a full 360˚, the unit will start to rotate and the head will immediately be opened. At
the end of rotation, the head will be closed and the unit simultaneously will be stopped.
When the blowing arc is less than 360˚, the blower still rotates through 360˚, but the head will be
opened and closed as determined by the position of the opening and closing cams in the drive
gear.
If it is necessary to adjust the actuation of the limit switches, refer to the instructions below:

B8.1 Setting the LSR Limit Switch

a) Remove the limit switch cover.
b) Insure the blowing cam is in the start position - the valve closed, with lever cam follower
between the opening and closing cams. (Reference Figure B8.2)
c) Loosen the lock nut on the limit switch to permit adjustment of the switch arm.
d) Set the switch trip arm to an angle of approximately 15 degrees. For units with clockwise
rotation, the arm must be installed at an angle above the trip pin and for counter-clockwise
rotation, below the trip pin. (The actual position may vary slightly depending on the limit
switch used). (Reference Figure B8.1)
e) Cycle the sootblower and confirm the unit stops in the proper start position. Repeat
adjustments may be necessary until the proper timing with the blowing cam is successful.
f) Secure the limit switch arm by tightening the lock nut.
g) Install and secure the limit switch cover.
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Figure B8.1
Limit Switch Adjustment
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Figure B8.2
Blowing Cam Start Position
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Test-Operate each blower before putting it into service. The points listed below should be among the
items/functions checked. The procedures in this section assume the boiler is not on line.

C1. TEST CHECKLIST

a. Make sure the element is properly supported and the nozzles are registered in the tube
lanes as shown on the application drawings.
b. Confirm that the element nozzles are positioned angularity as shown on the application
drawing. (Usually, nozzles are angled away from the gas flow to help prevent the nozzles
from becoming plugged.)
c. All strapping or blocks that have secured the blower during installation should be
removed.
d. Check the lubrication level in the gearbox.
e. Check all field wiring.
f. Check element rotation.
g. Check blower controls (local and remote).
h. Check valve actuation.
i. On partial (“limited”) sweep applications, make sure the head opening and closing cams
are properly registered with the angular position of the nozzles, as shown on the
application drawing.
j. Blowdown (Piping) Recommendation (see Addendum A)

ALWAYS USE CAUTION WHEN WORKING WITH MECHANICAL OR ELECTRICAL

EQUIPMENT. APPLY ONLY ACCEPTED, SAFE, INDUSTRY PROCEDURES FOR TESTING
AND OPERATING THIS AND RELATED EQUIPMENT.

C2. PRECAUTIONS BEFORE BLOWER TEST

a. Confirm that field wiring to the motor and controls are correct.
b. Always provide a means of immediate, local control of the power supplies to the blower
during service procedures. Secure and tag remote and local controls to prevent unwanted
operation by other personnel during test servicing.
c. Confirm that the blower is free of blocking, strapping, and foreign material.
d. Check the lubrication level in the power pack gearbox reservoir. (Refer to Section F1 –
Routine Maintenance for lubrication recommendations.)
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C3. ELEMENT ROTATION TEST

The drive motor must be wired to rotate the element in the proper direction when a “start” signal is
issued. Standard rotation is clockwise, but counterclockwise is available. Check the application
drawings for the correct direction of rotation.
a. To check the direction of the element rotation:
b. “Bump” the drive motor.
c. If the direction of rotation is wrong, correctly rewire per the wiring diagrams. (Check the
motor and the blower wiring.)

CAUTION!
IF IT IS DESIRED TO REVERSE THE ESTABLISHED ROTATION OF THE SOOT BLOWER
ELEMENT, CONSULT THE CLYDE BERGEMANN CUSTOMER SERVICE DEPARTMENT
FOR INSTRUCTIONS TO AVOID DAMAGING THE BLOWER.

C4. CHECK MOTOR STARTER CONTACT AND LIMIT SWITCH ACTUATION

a. Check the contact actuation of the motor starter:
b. Apply control power only.
c. Check the limit switch circuit to the motor
The non-reversing starter for rotary motion should be energized when LSR is tripped. (LSR is
held open in the at rest position.)

C5. LOCATION OPERATION TEST/CHECK MECHANICAL OPERATION OF LIMIT

SWITCH
Operate the blower from its local controls:
a. Test-operate the blower using its local START button. A signal will be issued to energize
the non-reversing starter.
b. The motor circuit should be locked in.
c. Observe blower actuation of the LSR limit switch.
d. The limit switch must be held closed and the motor circuit locked in for the blower cycle.
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C6. CHECK REMOTE CONTROLS

Check remote controls, if provided. The blower control should be the same as noted under
SECTION 3.4 above.

C7. CHECK DVT-FS HEAD VALVE ACTUATION

The DVT-FS head valve linkage is fabricated so the head opens immediately when the blower is
started. On full sweep rotaries, which blow for the entire 360˚ arc, the head is held open until the
blower stops. On limited sweep models, which blow for less than 360˚, the head will be opened
and closed as determined by the position of the opening and closing cams in the drive gear.
a. Confirm that the linkage is secure and that the nuts are tight.
b. Set blowing pressures at boiler start-up. See Section D - Operation for instructions.
c. Check that the head opens and closes properly. If not, refer to Section B - Installation for
instructions on adjusting the limit switches.
To assure tight seating of the valve in the closed position, there should be a minimum of 1/16”
clearance between the adjusting screw and valve stem cap.
 The hex valve stem cap is to be properly retained on the valve stem by a spring pin.
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D1. GENERAL NOTE

Prior to operating the D-5E rotary, confirm that it is mechanically and electrically ready for service
and that all related systems are operational. Refer to the procedures in Section C:
Commissioning.
USE CAUTION AND OBSERVE SAFE, INDUSTRY-ACCEPTED PROCEDURES WHEN
WORKING WITH ALL MECHANICAL AND ELECTRICAL EQUIPMENT.

D2. POWERED OPERATION

To operate the blower electrically:
a. Confirm that power and control circuits are correctly applied to the blower.
b. Depress the start button for a few seconds or press the button for blower start on the
remote controller.

D3. SETTING BLOWING PRESSURES

The DVT-FS head incorporates an externally adjustable pressure control device, which may be
set while the blower is on line. The pressure control device may be adjusted by rotating the hex
valve stem cap. The stroke adjustment screw should be adjusted so the valve is stroked to its
maximum open position – between 1/2” and 9/16”- to ensure the pressure drop exists at the
adjustable pressure control device.
CAUTION!
The hex valve stem cap should never be adjusted unless the valve is fully opened.
Rotating the hex valve stem cap while the valve is in the closed position may cause
damage to the seating surfaces. Lapping or machining of the seating surfaces may be
required to correct the damage.

To set the blowing pressure:

a. Install a pressure gauge with a 3/8” fitting downstream of the valve seat in place of the
existing 3/8” pipe plug.
b. Operate the blower with blowing medium.
c. Adjust the stroke adjustment screw so it strokes the valve between 1/2” and 9/16”.
Do not exceed 9/16” because it could damage the valve.
d. Note the blowing pressure.
e. If the pressure is greater than the recommended setting, rotate the hex valve stem cap
clockwise until the recommended setting is obtained.
 D-5E MKII Page 2 of 3 D
INSTALLATION, OPERATION
COMMISSIONING, OPERATION & 22 April 2007 Revision Number Preliminary
MAINTENANCE MANUAL Document I.D. D5EMKII.D1.0

If the pressure is less than the recommended setting, rotate the hex valve stem cap
counterclockwise until the recommended setting is obtained.
f. Let the blower complete its cycle.
g. Ensure a minimum clearance of 1/16” between the stroke adjustment screw and the valve
stem cap so the valve is capable of seating.
h. Replace the pressure gauge with the original 3/8” pipe plug, first making certain that
the blower will not operate during replacement and that the valve is properly seated
(see previous step).

D4. DETERMINING OPERATING FREQUENCY

The frequency of soot blower operation depends on the operating conditions of the boiler and on
boiler cleanliness. The need for cleaning may be indicated by:
a. An increase in boiler exit gas temperature.
b. A decrease in boiler gas flow.
c. Visual inspection
When a boiler is started up, it is most important to use the soot blowers soon and frequently.
Inefficient combustion during start-up may result in abnormal deposits on the tubes. Unless
removed frequently, they may later cause puffs or explosions.
It is also desirable to blow soot just before taking a boiler out of service.
When soot blowers are blown for the first time, increase the furnace draft as much as possible
during the blowing cycle. After several cycles, it should be evident how much, if any, the furnace
draft should be increased for future soot blowing.
Always increase the furnace draft when blowing soot while starting up a boiler or if blowing at low
boiler loads.
When the soot blowers are not in use, the main soot blowing medium supply valve should be
tightly closed and the system drain valves open.

D5. SUGGESTED BLOWING PROCEDURE

a. Increase the furnace draft as much as possible.
b. On steam blowing systems, open all thermal drain valves.
c. Open the main blowing medium supply valve slowly until it is wide open.
On stem blowing systems, never operate any blower until all piping has been warmed and
drained. Then, close the thermal drain valves.
 D-5E MKII Page 3 of 3 D
INSTALLATION, OPERATION
COMMISSIONING, OPERATION & 22 April 2007 Revision Number Preliminary
MAINTENANCE MANUAL Document I.D. D5EMKII.D1.0

d. Operate the soot blowers in the numerical sequence shown on the soot blower application
drawing.
e. Continue the blowing cycle by operating each blower in turn.
f. When the entire blowing cycle has been completed, close the main soot blowing medium
supply valve tightly. Open the thermal drain valves.
g. If the furnace draft has been increased for blowing, return it to normal.

Caution! Never Blow With Wet Steam

 D-5E MKII Page 1 of 1 E
INSTALLATION, TROUBLESHOOTING
COMMISSIONING, OPERATION & 22 April 2007 Revision Number Preliminary
MAINTENANCE MANUAL Document I.D. D5EMKII.E.0

E. TROUBLESHOOTING

PROBLEM POSSIBLE CAUSE SOLUTION

May require element material upgrade
Furnace temperature too high
Contact CBI service department
Drain lines of all condensate
Element Failure Check thermal drain valves
Excess water in soot blower
Insulate header.
header
Check steam supply header for the
proper slope
Faulty motor Replace motor
Frozen gearbox Replace gearbox
Element bond in the wall box or Realign the element
bearing Repair or replace limit switch
Blower Fails to Start
Faulty limit switch Reset overloads.
(Binding)
Overloads tripped Determine why tripped
Clean contacts or replace
Relays not making contact Check voltage
Clean and run blowers regularly
Check lever
DVT Head Closed Check for frozen valve stem debris
No Blowing between valve steam bushing
Medium/Flow Check pressure-reducing valve
Low header pressure Check for leaks in header
Check for other blowers blowing
Faulty motor
Replace motor
No lubricant in gearbox
Add lubricant per CBI instructions
Motor Gearbox Noisy Misalignment between motor
Realign motor and gearbox
and gearbox
Replace gears
Worn gears
Realign Nozzle
Nozzle misalignment
Blower Not Cleaning Check and adjust blowing pressure per
Incorrect blowing pressure
CBI instructions.
 D-5E MKII Page 1 of 6 F1
INSTALLATION, ROUTINE MAINTENANCE
COMMISSIONING, OPERATION & 22 April 2007 Revision Number Preliminary
MAINTENANCE MANUAL Document I.D. D5EMKII.F1.0

F1. MAINTENANCE SCHEDULE

Soot blower bearings and elements are continuously subjected to high gas temperature; therefore,
proper installation and maintenance are necessary to keep this equipment as trouble-free as possible.
To assure efficient operation and long life, establish and keep a good maintenance program.
Operating conditions at each side will dictate maintenance requirements. Initially, check the
equipment more frequently-until an effective schedule can be determined.
Clyde Bergemann recommends that plant personnel become familiar with the equipment.
This will assist in detecting abnormal conditions early.
USE CAUTION AND OBSERVE SAFE, INDUSTRY-ACCEPTED PROCEDURES WHEN
WORKING WITH THIS AND ALL MECHANICAL AND ELECTRICAL EQUIPMENT.

F2. VISUAL INSPECTION AND ESTABLISHING A MAINTENANCE SCHEDULE

F2.1 Initial Operation and Inspection
a. Make sure the soot blower mounting is secure. Loose mountings can cause the
jets of steam or air to be improperly directed inside the boiler, resulting in poor
cleaning and possible tube or baffle damage.
b. Confirm that all fasteners-especially those that retain main components-are secure.
c. Check for leaks at packing, gaskets and seals.
d. Observe blower operation, recording any abnormal operation or physical
conditions.
e. Inspect boiler area for blower cleaning effectiveness.
f. Check the blowing pressure if the blower is not cleaning properly.
g. After inspection, determine and schedule any required corrective action. Take
corrective action promptly to prevent possible damage and subsequent repair.
h. Record conditions to watch for on the next inspection.

F2.2 Weekly Inspection

The weekly visual inspection should become part of an on-going inspection procedure.
a. Check for evidence of lubricant or blowing medium leakage.
b. Make sure the soot blower mounting is secure.
c. Confirm that all fasteners are secure.
 D-5E MKII Page 2 of 6 F1
INSTALLATION, ROUTINE MAINTENANCE
COMMISSIONING, OPERATION & 22 April 2007 Revision Number Preliminary
MAINTENANCE MANUAL Document I.D. D5EMKII.F1.0

F2.3 After One Month of Initial Operations

a. Repeat visual inspection.
b. Confirm that no lubricant or steam leaks have occurred.
c. Check lubricant levels.
Check those components that require lubrication for evidence of insufficient lubrication
after the initial operation period. Record the condition and schedule lubrication to be
performed.
Record any abnormal or suspect conditions and schedule the appropriate physical inspection.

F2.4 Every Three Months

a. Repeat visual inspection.
b. Inspect packing, seal rings, and gasket areas for evidence of leakage.
c. Completely check the power pack. Tighten fittings to stop leaks or replace faculty
fittings and connections.
d. Inspect purge steam arrangement.
e. Check the external piping for leaks. Tighten fittings to stop leaks or replace faulty
fittings and connections.
f. Make sure the soot blower mounting is secure.
g. Check all points of lubrication. Re-lubricate as required.
h. Monitor blower operation.
i. Check valve operation and pressure.
j. Record any action taken at the time of inspection. Record all conditions requiring
action and schedule the required maintenance.

F2.5 Annually
Inspection and maintenance should be an on-going program. Soot blower bearings and
elements are continuously subjected to high gas temperature; therefore, proper installation
and maintenance are necessary to keep this equipment as trouble-free as possible.
Prior to a boiler shutdown, review existing records and make a complete, current inspection.
Schedule any maintenance that is required, including annual re-lubrication of gearboxes.
In addition to the normal inspection, also:
 D-5E MKII Page 3 of 6 F1
INSTALLATION, ROUTINE MAINTENANCE
COMMISSIONING, OPERATION & 22 April 2007 Revision Number Preliminary
MAINTENANCE MANUAL Document I.D. D5EMKII.F1.0

a. Check that the element and bearings are in good condition and are properly
aligned so the element rotates freely.
b. Check the nozzle locations to see that they register properly in the tube spaces.
Incorrect locations of the nozzles, brought about by wall movement, etc. may
cause the jets of steam or air to be misdirected, with the possibility of tube cutting
or baffle damage.
c. Check the element nozzles to make sure they remain round and are not elongated
by erosion by the blowing medium.
d. Check all element bearings to see that they are In place and in good condition.
e. Make sure the element end plugs are in place and not blown out or damaged by
slugs of condensate.

F3. LUBRICATON
(Refer to F2-Lubrication Chart)
F3.1 Drive Gears
Clean and lubricate the drive gears and all other external moving parts monthly with a
good grade of motor oil.

F3.2 Power Pack Gearbox

Check the power pack gearbox reservoir. Maintain the required lubricant level.
Clyde Bergemann recommends the use of Mobil SHC630 in the gearbox.

F4. CLEANLINESS
To assure long life and good performance of soot blowers, the outer surface should be cleaned of
dirt and rust periodically. If allowed to accumulate, dirt and rust will enter the operating
mechanism, causing excessive wear of moving parts and possibly preventing proper operation.

F5. PACKING
Keep glands just tight enough to prevent leakage; do not over tighten them. Replace packing that
leaks excessively.
Refer to Section G - Repairs for instructions on replacing packing.
 D-5E MKII Page 4 of 6 F1
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COMMISSIONING, OPERATION & 22 April 2007 Revision Number Preliminary
MAINTENANCE MANUAL Document I.D. D5EMKII.F1.0

F6. PREVENTIVE MAINTENANCE CHECKLIST

The following is a suggested preventive maintenance schedule. A regular maintenance program
that is compatible with conditions at installation should be established.
F6.1 Monthly
 Lubricate drive gears, etc.
Clean and lubricate the drive gears and all other external parts with a good grade of
motor oil.

F6.2 At Six Months Intervals

 Check limit switch.
Check limit switch is securely attached and operates correctly.

F6.3 Annual Maintenance

 Check the oil level in power pack gearbox.
Add recommended lubricant, if necessary. Refer to Section F2: Lubrication Chart.
 Check complete assembly.
Tighten loose bolts, nuts and cap screws.
 Test-operate each individual blower.
Using the local start button, operate each blower with the blowing medium of the unit
under the normal operating conditions.
 Check blowing pressure.
At the same time that the mechanical operation of each blower is being checked, the
blowing pressure should be checked (by gauge) in the DVT-FS operating head. The
recommended blowing pressure is shown on the application drawing.
This manual check is essential to assure that excessive blowing pressures, which
would cause boiler tube erosion, are not incurred.

F6.4 Periodically, As Determined By Installation Conditions

 Check motor starter cabinets.
Cabinets should be kept securely closed and gaskets should be in place to prevent
contamination.
 D-5E MKII Page 5 of 6 F1
INSTALLATION, ROUTINE MAINTENANCE
COMMISSIONING, OPERATION & 22 April 2007 Revision Number Preliminary
MAINTENANCE MANUAL Document I.D. D5EMKII.F1.0

If cabinets have been opened for servicing, carefully blow surfaces free of dust or
foreign material with light air pressure from a dry, clean air supply. Secure cover.
 Tighten or replace packing.
Packing in the valve stem in the DVT-FS operating head should be tightened. If
leakage is still present when packing glands are full down, the unit should be marked
for re-packing after the blowing medium is turned off and the header secured and
tagged.

F7. INSPECTION
Visually inspect the blower, checking that:
 Bolts are properly tightened
 Wiring is not loose or frayed, conduit is not broken
 Motor starter cabinet door is closed
 Steam or oil is not leaking around the seals
 No parts are missing
 Blower is properly supported
Check the condition of individual components and correct any problems. A list of components to
check and things to look for follows.

DVT-FS HEAD – Check for:

 Leaks-either visible or audible
 Broken or missing stem cap
 Missing valve stem cap
 Scavenger air valve leaking or missing
 Cracks
 Incorrect pressure setting
 Loose bolts
 D-5E MKII Page 6 of 6 F1
INSTALLATION, ROUTINE MAINTENANCE
COMMISSIONING, OPERATION & 22 April 2007 Revision Number Preliminary
MAINTENANCE MANUAL Document I.D. D5EMKII.F1.0

REACTION PLATE AND BULL GEAR- Check for:

 Missing or worn cams
 Worn or broken teeth on gear
 Broken reaction plate
(check especially around the element and where the switch box bolts on)

LIMIT SWITCH – Check for:

 Check switch settings (operational test required)
 Broken/frayed wires
 Loose mounting bolts

MOTOR STARTER CABINET – Check for:

 Broken/frayed wires
 Missing overloads
 Broken relays
 Chattering contacts
 Broken pushbuttons

MOTOR AND GEARBOX – Check for:

 Excessive Noise
 Oil leaks
 Loose bolts
 Binding
 Correct rotation
 Missing vent

WALL SLEEVE – Check for:

 Missing spring or seal plate
 Element flange assembly in place
 Page 1 of 1 F2
INSTALLATION,
D5E, D5M, D5ES, D5EMKII LUBRICANT CHART
COMMISSIONING, OPERATION &
22 April 2007 Revision Number 2
MAINTENANCE MANUAL
Document I.D. D5E.F2.12.2

F2.2 LUBRICANT CHART

COMPONENT METHOD FREQUENCY LUBRICANT QUANTITY

Inspect Every 6 Months.
Power Pack Reservoir Mobil SCH 630 10 OZ.
Lubricate if Required

Inspect Every 6 Months. General Purpose

Poppet Valve Operator As Required
Lubricate if Required Grease
 D-5E MKII Page 1 of 2 G
INSTALLATION, REPAIRS
COMMISSIONING, OPERATION & 22 April 2007 Revision Number Preliminary
MAINTENANCE MANUAL Document I.D. D5EMKII.G.0

G1. PRECAUTIONS
When servicing the blower:
a. Isolate blowing medium supply. Secure and tag off.
b. Remove electric power and control supplies. Secure and tag.
c. Be certain both local and remote locations are secured and tagged until the blower is
returned to service.
ALWAYS USE SAFE, INDUSTRY-ACCEPTED PRACTICES WHEN SERVICING THIS
EQUIPMENT.

G2. EMERGENCY SERVICE – MOTOR FAILURE

a. Remove electric power and control supplies to the unit.
b. Shut off the steam supply.
c. Replace the motor immediately.

G3. RECOMMENDED PROCEDURE FOR INSTALLATION OF PACKING

G3.1 Comments
The useful life of packing is dependent on the method of installation. Poor installation can
cause the best packing to fail prematurely. The methods in this procedure, if followed, will
lead to better sealing and longer life.
These packing methods apply both to installing packing in new equipment and to
replacing packing in equipment that is in service.
Replace packing when:
a. There is evidence of excessive leakage after the gland follower has been
tightened.
b. The packing has been compressed to less than three-quarters of its original
height.
c. The packing shows evidence of wear.
d. The blower has been disassembled for repair or regular maintenance.
It is more economical to automatically replace the packing when a blower is undergoing
maintenance than to incur labor costs and downtime later.
 D-5E MKII Page 2 of 2 G
INSTALLATION, REPAIRS
COMMISSIONING, OPERATION & 22 April 2007 Revision Number Preliminary
MAINTENANCE MANUAL Document I.D. D5EMKII.G.0

G3.2 To Remove Packing:

Flexible hooks are available for removal of packing. All old packing must be removed.
Inspect surfaces that are in contact with the packing. There should be no raised metal or
such surface that may damage the packing. Remove metal imperfections that project
above the normal surface. Do not try to rework depressions or scratches, as this would
only worsen conditions.

G3.3 To Install New Packing:

a. Keep packing clean and free of grit or debris, which could score sealing surfaces,
causing early failure of the packing.
b. Oil or grease may be applied to the outside of the packing to aid in installing it into the
stuffing box (packing gland).
c. Beveled packing is to be installed with the bevel lip that seats on the outside diameter
of a tube or shaft pointing toward the pressure.
d. Install packing rings one at a time, staggering the joints about 90˚ apart. Spot the
joints in a clockwise direction to facilitate locating them for removal later.
e. Each ring must be set firmly in place using the glad follower (or a tamping tool) as
required.
f. After each ring is installed, it must be compressed with approximately as much force
as will be applied at the final assembly.
g. Each ring should be equally compressed when the entire set is installed. If this is not
done, only the last ring will do the sealing and it will wear very quickly.
h. After the packing has been installed, tighten the gland follower to apply sufficient force
to assure final setting or packing, then back off to relieve excessive pressure.
i. Adjust the pressure on the packing to the operating conditions. Light gland pressure
should be maintained at all times. Too little pressure will permit excessive leakage
and cause the packing to be washed out. Too much pressure will cause binding or
scoring, resulting in failure of the seal and improper operation of the equipment.
j. Inspect the blower packing for degree of leakage as the packing wears in. Gradually
tighten the packing as it wears in after the blower has been in service.
 D5-E MKII Page 1 of 8 H1
INSTALLATION, EQUIPMENT SPECIFICS
COMMISSIONING, OPERATION & 22 April 2007 Revision Number Preliminary
MAINTENANCE MANUAL Document I.D. D5EMKII.H1.0

H1. ILLUSTRATIONS

FIGURE 1.1 – TYPICAL D5-E MKII ROTARY SOOT BLOWER

 D5-E MKII Page 2 of 8 H1
INSTALLATION, EQUIPMENT SPECIFICS
COMMISSIONING, OPERATION & 22 April 2007 Revision Number Preliminary
MAINTENANCE MANUAL Document I.D. D5EMKII.H1.0

FIGURE 1.1a – TYPICAL D5-E MKII ROTARY SOOT BLOWER

 D5-E MKII Page 3 of 8 H1
INSTALLATION, EQUIPMENT SPECIFICS
COMMISSIONING, OPERATION & 22 April 2007 Revision Number Preliminary
MAINTENANCE MANUAL Document I.D. D5EMKII.H1.0
 D5-E MKII Page 4 of 8 H1
INSTALLATION, EQUIPMENT SPECIFICS
COMMISSIONING, OPERATION & 22 April 2007 Revision Number Preliminary
MAINTENANCE MANUAL Document I.D. D5EMKII.H1.0
 D5-E MKII Page 5 of 8 H1
INSTALLATION, EQUIPMENT SPECIFICS
COMMISSIONING, OPERATION & 22 April 2007 Revision Number Preliminary
MAINTENANCE MANUAL Document I.D. D5EMKII.H1.0
 D5-E MKII Page 6 of 8 H1
INSTALLATION, EQUIPMENT SPECIFICS
COMMISSIONING, OPERATION & 22 April 2007 Revision Number Preliminary
MAINTENANCE MANUAL Document I.D. D5EMKII.H1.0
 D5-E MKII Page 7 of 8 H1
INSTALLATION, EQUIPMENT SPECIFICS
COMMISSIONING, OPERATION & 22 April 2007 Revision Number Preliminary
MAINTENANCE MANUAL Document I.D. D5EMKII.H1.0
 D5-E MKII Page 8 of 8 H1
INSTALLATION, EQUIPMENT SPECIFICS
COMMISSIONING, OPERATION & 22 April 2007 Revision Number Preliminary
MAINTENANCE MANUAL Document I.D. D5EMKII.H1.0
 D-5E MKII Page 1 of 3 H2
INSTALLATION, SPARE PARTS LIST
COMMISSIONING, OPERATION & 22 April 2007 Revision Number Preliminary
MAINTENANCE MANUAL Document I.D. D5EMKII.H2.0

H2. SPARE PARTS LIST

Note: This list is merely an aid to the selection of on-hand repair parts. The responsibility for editing
and selecting any or all parts lies solely with the user.

QUANTITY REQUIRED PER UNIT

PART QTY.
DESCRIPTION QTY. QTY. QTY.
NUMBER OVER WGT.
1 TO 5 5 TO 10 10 TO 20
20
268792 Gasket (Inlet Flange) 2 4 6 8 2 oz.
001964 Gasket (Element) 2 4 6 8 1 oz.

HEAD ASSEMBLY D-342922

342922 Basic Head Assembly 0 1 1 2
(Complete)
340136 Valve 1 2 4 6 1 lb.
078169 Spring Assembly 1 2 3 6 1 oz.
040783. Spring 1 2 3 4 1 oz.
342383 Stuffing Box 1 2 3 4 1 oz.
041060 Gasket 1 2 3 4 1 oz.
342382 Gland Bushing 1 2 3 4 3 oz.
343022 Packing Set (Grafoil) 3 6 9 12 6 oz.

INTERMEDIATE HEAD ASSEMBLY CBA006452

097097 Bearing 1 2 3 4 1 oz.
074228 Valve Lever 0 1 2 2 1 lb.
074559 Extension Tube Bearing 1 2 4 4 2 oz.
280864 Packing Ring Set 3 6 9 12 8 oz.
Grafoil)
001907 Snap Ring 2 2 4 4 1 oz.
289348 Drive Gear 0 1 1 2 15 lb.
194560 Bushing 0 1 1 2 8 oz.
006552 Key 0 1 1 2 1 oz.
264564 Gland 1 2 3 4 1 lb.

CAM ASSEMBLY L-160384

077377 Opening Cam 60º 1 2 4 4 3 oz.
077378 Closing Cam 60º 1 2 4 4 3 oz.
077376 Spacer Cam 60º 4 8 16 16 3 oz.
 D-5E MKII Page 2 of 3 H2
INSTALLATION, SPARE PARTS LIST
COMMISSIONING, OPERATION & 22 April 2007 Revision Number Preliminary
MAINTENANCE MANUAL Document I.D. D5EMKII.H2.0

H2. SPARE PARTS LIST

Note: This list is merely an aid to the selection of on-hand repair parts. The responsibility for editing
and selecting any or all parts lies solely with the user.

QUANTITY REQUIRED PER UNIT

PART QTY.
DESCRIPTION QTY. QTY. QTY.
NUMBER OVER WGT.
1 TO 5 5 TO 10 10 TO 20
20
077429 Opening Cam 60º CCW 1 2 4 4 3 oz.
077430 Closing Cam 60º CCW 1 2 4 4 3 oz.
040632 Flat Head Screw 6 12 24 24 1 oz.
086682 Spacer Cam 30º As Required

SWITCH BOX ASSEMBLY CBA006450

As specified Limit Switch (LSR) 2 2 2 4 1 lb.

POWER PACK ASSEMBLY CBA006450-GEARMOTOR/L-160141

CBA006450- Power Pack Assembly 0 2 2 2 25 lb.
GEARMOTOR (Complete)
032623 Bearing 0 1 2 2 3 oz.
032624 Bearing 0 1 2 2 3 oz.
032613 Seal 3 3 6 9 1 oz.
186226 Coupling Gear 0 1 2 2 2 lb.
032697 Gear Retainer 0 1 2 2 1 oz.
004834 Key 0 1 2 2 1 oz.
006591 Washer 0 7 7 14 1 oz.
006666 Gear 0 2 2 4 1 lb.
019275 Spacer 0 2 2 4 1 oz.
006584 Bronze Bushing 0 2 2 4 1 oz.
006667 Gear 0 1 2 2 1 oz.
006587 Bronze Bushing 0 1 2 2 1 oz.
006668 Gear 0 2 2 4 1 lb.
006588 Bronze Bushing 0 2 2 4 1 oz.
268788 Gasket 2 4 4 6 1 oz.
 D-5E MKII Page 3 of 3 H2
INSTALLATION, SPARE PARTS LIST
COMMISSIONING, OPERATION & 22 April 2007 Revision Number Preliminary
MAINTENANCE MANUAL Document I.D. D5EMKII.H2.0

H2. SPARE PARTS LIST

Note: This list is merely an aid to the selection of on-hand repair parts. The responsibility for editing
and selecting any or all parts lies solely with the user.

QUANTITY REQUIRED PER UNIT

PART QTY.
DESCRIPTION QTY. QTY. QTY.
NUMBER OVER WGT.
1 TO 5 5 TO 10 10 TO 20
20
013971 Air Vent 2 4 8 8 1 oz.
031726 Spindle (Power Pack) 0 1 1 2 6 oz.
013736 Key (Spindle) 0 1 1 2 1 oz.
006596 Pinion 1 1 2 2 1 oz.
006570 Key 1 1 2 2 1 oz.
As specified Motor
278056 Power Pack Lubrication- 1 pt
Mobil SHC 630
 THE INFORMATION CONTAINED IN THE DRAWING IS THE SOLE PROPERTY OF
CLYDE BERGEMANN, INC. ANY REPRODUCTION IN PART OR WHOLE WITHOUT
REVISIONS
THE WRITTEN PERMISSION OF CLYDE BERGEMANN, INC. IS PROHIBITED.
REV. DATE BY DESCRIPTION ECN

8
7

6
3
4

5
2

9 1

"B"

ITEM CBA006450-480
PART NUMBER DESCRIPTION
NO. GEARMOTOR/QTY.
1 160141 POWER PACK, BSC D5 ASSEMBLY 1
2 031726 SPINDLE, NEMA 5/8 MOTOR TO POWERPACK 1
"A" 3 004869 SET SCREW 1/4-20 X 1/4 CUP POINT 2
4 013736 KEY, .19X.88 STEEL AISI 4140 1
5 006596 PINION, 20TOOTH 24P STEEL 0.31F 1
6 006570 KEY, .12 X.31 AISI 4140 STEEL 1
7 014552 SCREW, HHCS 1/4-20X3/4 GR5 4
LUBRICATING INSTRUCTIONS 8 004329 WASHER,LOCK .25IN SHAKEPROOF INTERNAL ZP 4
UNIT UP RIGHT-FILL TO OIL LEVEL HOLE "A" 9 CBA006451 MOTOR, 480V CPO 1
UNIT WITH RIGHT SIDE DOWN - FILL TO OIL LEVEL HOLE "A" THIRD ANGLE UNLESS OTHERWISE NOTED
DIMENSIONS ARE IN INCHES.
BY DATE
4015 PRESIDENTIAL PARKWAY
PRJECTION
LOOKING FROM MOTOR END - " " " " " " DRAWN MTH 8/9/06 ATLANTA, GA. 30340
TOLERANCES ARE:
XX XX/XX/XX
UNIT UP SIDE DOWN - FILL TO OIL LEVEL HOLE "B" CHKD. P. 1 800 241 5996 F. 770 557 3600
FRACTIONS = 1/64 WWW.CLYDEBERGEMANN.COM
APPD. XX XX/XX/XX
UNIT WITH LEFT SIDE DOWN - FIILL TO OIL LEVEVL HOLE "B" DECIMALS .XX = .01 .XXX = .005
NEXT ASSY
LOOKING FROMOTOR END - " " " " " " ANGLES 1
D5E, 480V GEARMOTOR
SURFACE FINISH = 125 USED ON
UNIT WITH SHAFT POINTING UP - FILL TO OIL LEVEL HOLE "C" BREAK ALL SHARP EDGES D5E SIZE DRAWING NUMBER REV.
UNIT WITH SHAFT POINING DOWN - FILL TO LEVEL HOLE "C" MATERIAL/HARDNESS FINISH
CBA006450-480-GEARMOTOR
PER B.O.M B SHEET 1 OF 1
0
 Page 1 of 1 00
INSTALLATION,
SEPARATION PAGE
COMMISSIONING, OPERATION &
30 June, 2004 Revision Number 1
MAINTENANCE MANUAL
Document I.D. Separation Page.00.1

THIS PAGE INTENTIONALLY LEFT BLANK

TO PROVIDE SEPARATION BETWEEN

MANUAL

AND

PROJECT SPECIFIC DOCUMENTS

 D-5E MKII Page 1 of 2 Addendum A
INSTALLATION, Blowdown (Piping) Recommendation
COMMISSIONING, OPERATION & 27 September 2010 Revision Number Preliminary
MAINTENANCE MANUAL Document I.D. D5EMKII.Add.A1.0

Purpose: To provide requirements and cleaning procedures for steam blowing/cleaning of steam
supply lines that service sootblower systems.

Scope: This document covers the requirements needed to test, clean, and preserve a steam
system that will supply a sootblower system.

Test #1:
A hydro test may be performed to check for leakage of the new piping system. Prior to this type of test
being performed, the system should have the following checks done:
a. Plant safety procedures should be in place to barricade the area of the system that is being tested.
b. All safety relief valves should be gagged to prevent lift off during the test.
c. All control valves removed and straight spool of pipe installed.
d. All in-line valves fully opened.
e. A blind flange or pancake plate should be installed at each sootblower connection point.
f. Any in-line instruments, such as orifice plates should be removed to prevent damage.
g. All of the hangers should be checked to ensure proper support of the system that is to be tested.

Once all these tasks have been performed all of the air should be expelled from the system. No insulation
can be installed on any pipe joints, prior to hydro testing. The hydro test is usually performed at a minimum
of 1 ½ times the design pressure of the system. The length of the test is based on the time required to walk
the system down to visually inspect and mark any leakage points. Should leaks be detected, the system
should be drained, leaks repaired and the system re-tested. Once no leaks are located/detected, the
system should be safely drained. The piping system could be insulated after a successful hydro test has
been performed and signed off.

Test #2:
A steam blowing test is performed to clean the inside of the piping system of any foreign material.
Blowing through the sootblower and poppet valve is not permitted. It can cause severe damage to the
sootblower. Prior to the steam blowing test, the following tasks should occur:
a. The steam should be superheated to assist in removing internal scale for the piping system.
b. All safety relief valves should be operational.
c. All spring hanger shipping pins and/or locking devices shall be removed.
d. All spring hangers should be checked to make certain the hangers are set to the cold setting.
 D-5E MKII Page 2 of 2 Addendum A
INSTALLATION, Blowdown (Piping) Recommendation
COMMISSIONING, OPERATION & 27 September 2010 Revision Number Preliminary
MAINTENANCE MANUAL Document I.D. D5EMKII.Add.A1.0

e. Either a pancake or blind flange is installed, prior to each poppet valve.

f. On the branch line that supplies steam to the sootblower that is to be cleaned; the flange connection
to the poppet valve is disassembled and a spool piece is added to safely discharge the exit gas and
any foreign contents to a safe location.
g. Care should be taken to be sure this discharge line is adequately supported to absorb/withstand the
reaction forces that will occur during the steam blowing cycle.

The steam blowing cycle should start with the branch line that is the highest in the system and the
longest distance from the main supply header. Several blows will be required to adequately remove the
foreign material from the supply line. During the blowing cycle, it is preferred the internal temperature of
the line reach a minimum of 400F. If the client requires, a 1” polished target could be inserted in the
temporary spool piece of pipe to check for particle impingement. Once the branch line is cleaned, the
spool piece should be removed, either a blind flange should be installed or a pancake installed to isolate
and prevent damage to the poppet valve. The testing should continue until all branch lines have been
adequately cleaned. The low point trap station(s) should have the strainer basket removed and cleaned.
Should the sootblower steam system be required to sit dormant for several months, a nitrogen blanket of
approximately 5 lbs. should be placed on the system to minimize rust reforming on the inside of the
cleaned steam pipeline.

After a successful and completed steam blowing test:

1. Remove any temporary installed blind flanges or pancake flanges and reattach the steam lines to the
sootblower poppet valves.

2. Remove any pipe spools or temporary pipe plugs and reinstall the control valves and in-line
instruments.
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Vulcan trademark is used under license from
Copes-Vulcan