Rotating Ash Cooler

Installation and Operation Instructions

Manufacturer: Songling Power Environmental Equipment Ltd.

10
Address: 10 Gaozhou Road, Jiaozhou City, Qingdao, Shandong Province, China

0086-0532-82270222

0086-0532-82271156

Tel0086-0532-82270222 Fax0086-0532-82271156
www.qdsongling.com

qdsongling@vip.163.com

Website: www.qdsongling.com Email: qdsongling@vip.163.com

Catalogue
. Summary
. Main Structure
Working Principle
. Water System Protection
. Installation
. Function
Current Maintenance
Check and Repair
. Common Failure and Treatment
. Spare Parts
. Special Attentions
. Danderous Operation
1
Figure 1 Rotating Ash Cooler Working Principle
2
Figure 2 Rotating Ash Cooler Outside Drawing
3
Figure 3 Diagram on Rotary Joint and water pipe


Installation and Operation Instructions
for Rotating Ash Cooler
. Summary

950
150

50

Rorating Ash Cooler is used for cooling the hot ash(about 950) in circular fluidized
bed Boiler. The ash temperature after cooling will be less than 150 generally.
The main cooling method used by the Ash Cooler is water cooling, supplemented by
air cooling. Affect heat transfer ,so the temperature of output generally should not be more
than 50 , need timely removal
The coolent used for the Rotating Ash Cooler is softened water suitably ,steam turbine
condensation water generally is used. industrial water scaling easily which will affect heat
transfer ,so the temperature of output generally should not be more than 50 , need timely
removal.
The ash coolers are classified into left-handed type and right-handed type by motor
position. Seen from ash outlet of ash cooler, the motor fixed on left side of the barrel is what
left-handed ash cooler, while the motor fixed on right side of the barrel is what right-handed
ash cooler.
.
Main Structure

Rotating Ash Cooler is composed of a barrel, rotary system, drive mechanism, ash
inlet section and ash outlet section, cooling water system and electric control system
etc.(more details see the attached drawings)
1
2

1. Barrel: The barrel is composed of inner shell, outer shell, heat transfer counter vane and
end cover . Heat from hot ash shall be transmitted to the circular cooling water via helical
fins and longitudinal fins welded on the inside wall of the inner shell, by means of
conduction, convection and radiation etc.
2

2. Rotary System: The Rotary system is composed of support ring, support roller , axial
guide rollers ,drive sprocket, and driven sprocket. The and support ring install outside the
roller .Support ring and driven sprocket are fixed on the outside of the barrel and it will drive
the barrel to revolve on the four support rollers driven by the driving motor. The abrasion of
support ring support roller can lead to the barrel height falling down. Bolt in the bottom of
the ash inlet device shell keeps seal ring, sealing ring and seal cartridge concentric. The
axial guide rollers are installed on both sides of the ash outlet section to the barrels axial
displacement.
3
3. Drive mechanism: the drive mechanism is composed of electrical machine and speed
reducer etc,which can provide power for barrel.
4

4. Ash inlet section: the ash inlet section is composed of the down spout, ash feeding tank
and ash anti-leakage device etc.. The bottom ash flows into the barrel via ash inlet through
ash down spout. There is an air vent with negative pressure in the ash feeding tank. The
contour screws in the anti-leakage system are designed to prevent ash leakage.
5

5. Ash outlet section: the ash outlet section includes seal cover and ash outlet etc. Air vent
3

with negative pressure and as accident release vent are designed as your requirement.
The seal cover can be made from two pieces disassembled, which is convenient for
maintenance.
6

6. Cooling water system: the cooling water system is composed of rotary joint, water pipes
at barrel end, return water pipes, flexible metal tubing etc, which can provide cooling
water.The rotary joint is equipped with pressure gauge, hot resistance and safety valve.
These safety attachment are fixed above the cooling water pipe.
7
7. Electric control system: mainly includes control cabinet and related control instruments,
and output the remote signals to control the Cooler remotely.
8
8. Ash inlet pipe component: range from ash outlet on the boiler to ash inlet on the ash
cooler, include ash pipe and connector flange.
. Working Principle

The hot ash discharged from boiler flow into the top end of the barrel through ash down
spout and pile up to a certain height surrounded the ash down spout.When the force of
gravity is balanced with the gravity of the ash flow, the ash flow in the ash down spout will
be prevented; When the barrel rotates and conveys the ash to the outlet end, the height of
the ash pile will discend and break the balance so that the ash flow will continue. In this
case, the hot ash flows into the barrel with its rotating and stop when the barrel stop rotating.
In the process of conveying ash, heat exchange occurrs between the ash and cooling water
and the cooling water reduce the temperature of the ash by taking most of the heat away.
4

Water system protection

It is possible to cause danger for the equipment works when the cooling water system
pressure exceeds the barrel allowable stress. Therefore, ordinary maintenance of the ash
cooler should be as per Pressure Vessel Regulations, and design the following protections
for ash cooler cooling water system.
1

1.Interlock between ash cooler operation and electric valves that installed at cooler
water inlet and water outlet, namely, the ash cooler should start up after opening the water
inlet and water outlet valves.
2

2. The pressure switches mounted in the cooling water system shall alarm signal at
low pressure or overpressure of cooling water system and stops the cooler operation.
3

3. The hot resistance in the cooling water system shall alarm signal at cooling water
system over temperature and stop the cooler operation.
4

4. The safety/relief valves mounted on the cooling water system shall discharge the
overpressure cooling water.
5

5.The axial displacement detector shall alarm signal over axial displacement limit and
stop the cooler operation.

Above mentioned protection measures and safety attachment should be verified

regularly, twice a year generally.
. Installation

()

3mm
Hydraulic testing on the barrel has been done for the ash cooler before EXW, as well
as the whole machine test running. The ash cooler is wholely assembled for shipment
except some pipes, expansion joint, valves and attachment, which require field installation
and interconnection.
The ash cooler should be located correctly according to the installation drawing and
collocation plan while installing. The ash inlet aims at the boiler outlet with levelness
3mm. The bottom base should be welded firmly with the basic embedded parts.

Special attentions for field installation

1

1. The ash coolers are classified into left-handed type and right-handed type by motor
position. Seen from ash outlet of ash cooler, the motor fixed on left side of the barrel is what
left-handed ash cooler, while the motor fixed on right side of the barrel is what right-handed
ash cooler. The drive constructure requires field installation after the whole machine located.
Pay attention to the rotating direction of the barrel which should not be installed conversely.
2

2.The drive constructure requires field installation after the whole machine located.
Pay attention to the rotating direction of the barrel (The rotating direction is painted on the
outlet seal cover.). The below chain is tight chain, which should not be installed conversely.
3

3. Speed reducer will not fill lube oil for shipment convenience. The lube oil should be
clean and filled as the instruction before running.
4


4. Please noted that the rotary joints should not hit each other while installing to
prevent from water leakage and large rotating vibration. The water pipe connected with the
rotary joint should have a good deflection, the fixing point should be properly away from
water inlet and outlet in order to protect the metal tube. One end of the metal tube joints
with the water pipe and the other with rotary joint. The funnel below the rotary joint has a
water outlet, which should lead into the drain.
5
()
350

5. After the location of the ash inlet air vent and dust absorption vent on the ash outlet
are assured, welding work will be done on the ash feeding tank. Flanges are welded to the
antipressure air pipe, which is connected to the inlet before the dust removal or the
chimney in the end of the boiler. The antipressure air quantity and the diameter of air pipe
are confirmed as per the project. In order to compensate the thermal expansion, the air vent
on the ash inlet end is flexible interface. Dont plug the short pipe in the end. The
antipressure air pipe requires to design a manual adjusting damper.(Temperature
resistance 350)
6
safety zone smooth

6 After the whole ash cooler is installed completely is the observe and control
instrument, just as the hot resistance, pressure gage or pressure switch including the safety
valve. Keep the safety valve installed vertically ,the outlet is in the , safety zone and smooth.
The location and height of the electronic control cabinet hanged on the steel pole of the
boiler should be for operation convenience,out of fire.

7. The electronic equipment should be connected according to the wiring diagram.The

signal connected with central control room in the drawing must be connected and keep
unblocked. The rotating direction should follow the marks on the ash cooler and be
connected, with reversion not allowed. The wires on each testing point should be in good
condition for good signals.
. Running
1 Non-load Running testing

Before test running, remove the iron which installed under the support ring to prevent
the movement in the transportment process.

10

Flush the ash cooler cooling water pipelines. Connects reversely between the water
inlet and the outlet and connects to cooling water and flush threel times at least until the
clean water flow out,every time is not less than 10 minutes. Flushing process should
conduct at the low speed of the barrll(Release the interlocking in the flushing
process,recover the interlocking after finishing the flushing. ).

30

Before test running,confirm the rightness of the cooling water connector,and then pour
the water. Turn the barrel to the position that the vent upwards, then turn-on the exhaust
plug to discharge the air until the water flow out from the vent, and then plug for seal. Pour
the working pressure cooling water,and keep the pressure for 30 minutes,and check
leakage, transformation and unusual sound.
2

Carry out alarm signaled and stop automatically under the condition that cooling water
over pressure and less pressure test at least twice.If cooling water pressure surpass the
pressure switch set-value,the safety protection system alarm should signal and stop
automatically the cooler operation immediately. Also, the water pressure rise to the opening
pressure of safety valvesafety valve, relief pressure and protect the equipment.
6

All of them are in normal condition then pour normal cooling water.Experience at least
six hours continuous test run (must be connected to cooling water), check operation of the
ash cooler ,if there arent any abnormal then goes to productive operation.

The rotary joint allows a little leakage ,Adjust the tightness of packing glands
compression bolt if the leakage is too great.

start up the ash cooler without cooling water.

Dont

2.
2. Preparing before running
2.1
The cooling water system must be assured to put into operation before the ash
cooler starts up.
2.2
Start the motor, observe whether the rotating direction of the barrel is right.
2.3
Check whether the electronic control cabinet and electrical equipment work well.
2.4
Check whether the air door of the antipressure air pipe is open.
2.5
Check whether the protection setting value meets the requirement.
3 Running
5Hz


The rotating speed of the barrel can be adjusted by the transducer with frequency 5HZ.
After startup the speed can increase to fit the ash output quantity,and every raising speed
should not be too great. Please try the best to make the machine work at low speed under
good conditiion of the bedding pressure.

Note that the ash cooler should work continuously,or do harm to the ash cooler easily.
95

Temperature controller can be set to alarm at 95 when the coolent is desalted water.
Special cases should gain our technology departments agreement.

The control valve of the water inlet pipe must be connected with the ash cooler. It is
prohibited to start the ash cooler without water or having insufficient water.

Find out causes and solve the defects ,forbid the protect components short-circuited or
canceling the protection function,when the ash cooler stops working because of the
protection function.

In the running process of the ash cooler, especially at the beginning of running,
sometimes appear that the hot ash flow directly to the outlet (even the next level equipment)
under the effect of positive pressure (This phenomenon is usually called scoria flow)
because the boiler is under an unstable working condition or with coke. There is no
regularation for scoria flow, but has some foretoken: The whole ash inlet pipe turns red and
10

the temperature of return water increases sharply. The ash inlet and outlet are with heavy
smoke and with it the hot ash will flow to the ash outlet. With rapid drop of the boiler
bedding pressure, the ash cooler should be shut down immediately and re-start after the
temperature of return water returns to normal. After restart, the rotating speed should
contron below 30Hz and determine whether to raise the speed as the case.

20
2030

Dont immediately stop the cooling water when stops working,delay 20-30 minutes at
least,or will damage the ash cooler becase of overheating.

Routine maintenance

6
Adjust the tightness of seal stuffing properly in the inner end of the rotary joint and
replace them in time if worn. Generally all should be replaced after working for 6 months.

15mm

15mm
Check the bear of the rotary joint regularly. The abrasion extent of the thrust axletree
can be indicated by the distance between the surveyors pole and shaft shoulder of rotary
joint: With the increasing of abrasion on thrust axletree, when the distance extends to
maximum 15mm, the thrust axletree should be replaced then.
5mm

5mm
0.0mm
11

 510mm
The barrel may descend because of the adrasion of the support ring and support roller
after long time operation, and the allowable decrease is 5mm.In order to check the height of
the barrel, there is designed a testing equipment of the height of the barrel below the ash
inlet, which is composed of upper arc panel, lower arc panel and proximity switch. When
the upper arc panel goes to the lowest location with the barrel, the gap between the upper
panel and lower panel is 5mm. When the height of barrel decend because of the adrasion
of the support ring and support roller and the gap between the upper panel and lower panel
is close to zero (the proximity switch will alarm), adjust the barrel height in time and make
the gap between the upper and lower panel 5-10mm. (This gap requires field adjustment
because there may be error about the outer diameter of the barrel.)

The optimum axial position of the barrel is that the gap between support ring end faces
and two side axial guide rollers are approximately equal. Adjust the axial guide rollers
during operation to optimum position if there is serious deviation between them. The axial
displacement detecting device is arranged at the axial guide rollers and the control system
alarm signaled when the axial displacement is out of the limit.

Readjust the support rollers position if the axial displacementment is too great.

The wearing parts included in the anti-leakage construction such as the ash enclosure,
the ash seal loop and ash inlet pipe shall be repaired or replaced once ash leakage is found
due to the abrasion.
When replace the ash enclosure and the ash seal loop, take away the ash inlet pipe
previously, and readjust the barrel height and the gap between them to prevent ash
leakage.
12

The ash seal loop is fixed on the ash inlet pipe face by stainless steel bolt and nut. It
requires to cut down the seal enclosure and clean the weld seam when replaced and adjust
the seal gap when reinstalled.

Checkout the alarm signaled and stops automatically when cooling water over
pressure, thermometer and the safety valve discharge once every half year operation.
Calibrate the pressure gage and any other safety accessories as per relevant regulations,
and replace any unqualified ones.

If the ash cooler is left idle for long time, check the rusty condition of the rotary joint
inner axeltree and the nuts. Replace them before operation if the rusty condition is serious.

Check and Repair

The Rotating ash cooler shall be managed as per the pressure vessel.

#2
In addition, check the lube oil level of the speed reducer and add correct amount of oil
timely according to the instructions during the running process. Keep the cooling fan motor
in normal operation. Lubricate the support rollers regularly with special lithium base grease
using grease gun.

The ash cooler chain s degree of tightness is proper,or reduces efficiency.. If the
take-up stroke to the limit, dismantle some chain links or replaces the chain completely.
13

The ash cooler axial displacement is limited by axial guide rollers, whose diameter is
far smaller than support ring. So they are abrased fast and need replacement regularly if
worn.

In the cold region, Blow down all the water vis the air bleeder in case of damage the
ash cooler if it cant put into operation or stop working .

When the roller bladess attrition influence the output, change it in time

Common Failure and Treatment

1-2

15mm

14

#2

2kg

#2

8kg

500

When the ash cooler gets troubled, analyse the reason and take record, deal with the
problem in time. The following form about coommon Failure and treatment is for your
reference.
15

Common Failure and Treatment

Failure Description

Reasons

Reference Treatment
Adjust compaction extent
of the seal stuffings cover.

Serious abrasion of the seal If

stuffing

it

can

compressed

not
any

be
more,

Serious leakage on the rotary

replace 1-2 stuffings or
joint
replace totally.
Adjust the cover to the
Capped end inner cover is off
same centre with the core
centre
pipe
seal stuffings are abrased.
Axletree

and

nuts

Replace
are
Replace

Rotaty joint shell move out damaged.

over 15mm

Hollow shaft nut drops

Re-install

Hollow shaft is abrased

Replace

The shell is abrased

Replace
Adjust displacement and

Axial

guide

rollers

are The barrel axial displaces too

replace the axial guide

seriously abrased.

much.
roller.
The support ring and support Replace the support ring
roller are abrased seriously. and support roller, adjust
The barrel descend and hit the the clearance with the ash

The

barrel

smoothly,

doest
with

rotate

stuck

vibration phenomenon.

or

ash inlet pipe.

inlet pipe

There are some sundries on

the friction surface of the Clear away
support ring and support roller.
The ash enclosure and ash Adjust
16

the

clearance

seal loop contact with friction.

between them

The barrel axial displaces too Adjust the displacement

much.
Serious ash inlet leakage

Seal

and clearance
gland

is

seriously

abrased and the clearance is Replace

too large.
The quantity of the ash is Increase
unstable
The temperature of the return
water

and

ash

increases

and

increases speed

sharply.

the
and

rotating
start

the

standby ash cooler.

The cooling water system is

check and clear out

sharply.

blocked.
scoria flow occurred.

Stop the ash cooler

lack of lubrication

Add lubricating grease

Replace the chain and the

The chain doesnt mesh well serious abrasion

chain wheel
with sprocket, with one side
abrased seriously.

Excessive chain slack

Tighten the chain

The chain and sprocket are

Re-adjust
out of alignment.
The axletree is damaged.

Replace

The barrel axial displaces too

Adjust the displacement

The support roller works with much.

noise and stuck.

There are some sundries on

the friction surface of the Clear away
support ring and support roller.

Lubrication List for the Ash Cooler:

No.

Lubrication

Oil amount for Period

Lubrication Medium

Point
1

The

Remarks
each set

support #2 special lithium base

17

2kg

roller

grease

months

components
2

The axial guide

#2 Commen Lithium
rollers

3
8kg

base grease

months

components
The first 500

No.46

hours of

Industry Subject to the operation to replace new oil

Speed reducer
lubricating oil

oil level line

and replace once every six

months later.

. Spare parts

10

11

12

13

1
2

Spare parts required by the Rotating Ash Cooler is as below form, please purchase on
your demand. Details of the location see attached picture.
No.
1

Description
Rotary joint

Installation Position
Outlet end

Remarks
One piece per unit, left and right

18

Packing Glands

Rotary Joint Outer

Many kinds

End
3

axletree

Rotary Joint Outer

One piece per unit

End
4

O Seal Ring

Rotary Joint

Axial Guide roller

Rotating

Many kinds
Barrel

4 pieces per unit

Under the rotating

4 pieces per unit

Side
6

Support roller

barrel
7

Seal gland

Ash Inlet end face

one set per unit, including seal ring and

seal enclosure, left and right

Support Ring

The barrel

2 pieces per unit

Big Sprocket

The barrel

one piece per unit

10

Sprocket

Speed reducer

one piece per unit

11

Bush

Roller Sprocket

One piece per unit

Chain
12

Speed reducer

13

Flexible

Include the power motor and axial flow fan

Metal Rotary joint

2 pieces per unit

Tube
Instruction:
1. Detailed specification and Model No., please contact our technical department
2. Rotary joint, Seal ring and Seal enclosure are classified to left and right types, please
mark it while purchase.
.

Dangerous Operation
1
2

3
4
5
6
7

19

1. The entrance flashboard door of the four Ash cooler is closed when start the boiler but
the barrel is rotating. In this case, the ash pile in the ash cooler will be damaged.
2. Under the condition of high bedding pressure and evacuation, the inlet door is opened.
In this way, a mass of red ash will discharged fast from the ash cooler.
3. The ash cooler is stopped due to ash eruption. If you restart the ash cooler in a very
short period of time, ash eruption will occur again.
4. Start the ash cooler when the cooling water inlet and outlet valves are not open and the
cooling water system does not work.
5. The safety attachments like the pressure switch, safety valve are put into operation
without checkout.
6. Forced to run the ash cooler under the condition of the barrel axial displacement and the
barrel height being over limit
7. Find out causes and solve the defects ,forbid the protect components short-circuited or
canceling the protection function,when the ash cooler stops working because of the
protection function.

20

Attachment
LGTLGT-DKX

Operation Instructions of the LGT-DKX electric control cabinet

on Rotating Ash Cooler

1 Brief Introduction
LGT-DKX

LGT-DKX Electric Control Cabinet is the electric control device equiped for Rotating
Ash Cooler. It can control the ash coolers work and adjust its speed. Meanwhile, the
control system can check the water temperature, water pressure, barrel displacement and
the barrel descent limit, alarm signaled when the barrel height decreases after long time
runing; alarm signaled and stop the machine under the condition of water break,
overpressure, over displacement and other failures.
2
Installation and Connection

After the machine is installed, hang the electric control cabinet on the handy steel pole
of the boiler and connect according to the wiring diagram of the Rotating Ash Cooler (The
shield layer for cable shield should be grounded.). The shell of the cabinet should be
grounded.
3 Debugging

/
Before debugging, check whether the machine is installed and connected correctly and
21

whether the electric component and screws in the cabinet loose. Power on for debugging
after confirming above. There are two ways to debug, local and remote.
Local debugging

Check whether the water pressure at the rotary joint is within the setting limit. (This limit
is set according to the actual value of the water cycle system). If the water pressure is lower
than the minimum or higher than the maximum, the Ash Cooler can not start and the related
indicator will light on the operation board. Please start the ash cooler for debugging after
confirming the water pressure within the setting limit.
QF
/

Firstly turn on the power switch QF in the electric control cabinet and the indicator
lights.

There

will

be

indication

on

the

transducer

panel.

Please

aim

the

Local/Romoteswitch at Local and press Start to start the ash cooler. Check the rotating
direction and correct the direction as requirement.You can adjust the speed of the ash
cooler to achieve the desired rotating speed through pressingSpeed Upbatton and Speed
Down batton.
4-20mA

The Romote debugging can be done after the above operation is finished
correctly.( Namely, make the ash cooler adjust the rotating speed Automatically with
changes of 4-20MA current signal.)
22

/
420mA
420mA

Aim the Local/Romoteswitch at Remote and the ash cooler will start, stop and adjust
the rotating speed in the distance. Press the batton of Start to start the ash cooler and
adjust the input of 4-20MA current signal to make the rotating speed vary with the current
signals. At the same time the transducer will return the last 4-20MA current signal to the
centre control room to test the speed of the ash cooler. You can press the Stop batton to
turn off the ash cooler if you want.

95

Water overtemperature alarm, water break, water overpressure, barrel displacement

overlimit are the protection function designed for the safe running of the ash cooler. Water
temperature is tested by the hot resistance equiped on the outlet of the cooling water. When
the water temperature is higher than the setting temperature (95 generally), the system
will alarm and remind the user to check the equipment in case of accident. The alarm will
disappear automatically with the water temperature drops to below the setting temperature.

Water break, overpressure are tested by the pressure gage equiped on the outlet of the
cooling water. The ash cooler will stop automatically and alarm signaled with water break or
overpressure, which need the user to check and adjust the water pressure to make sure the
ash cooler runs normally.
Barrel displacement and discent are tested to prevent the barrel from running under
abnormal condition.
4

HL1

23

HL2

HL3

HL4

HL5

HL6

HL7

HL8

4. Functions of indicator lights

HL1 Power indication
HL2 Water temperature testing indication
HL3 Barrel displacement overlimit indication
HL4 Barrel discent indication
HL5 Runing indication
HL6 Failure indication
HL7 Water break indication
HL8 Water overpressure indication
Meanwhile, there reserves some remote connection signals for running, failure, water
break, water overpressure, barrel displacement and barrel discent of the ash cooler to help
the user testing the ash cooler status in the distance.
5

5. Attention
The interior parameter of the transducer is set before Exworks. Dont modify it if no
exceptional requirement. If the change is really necessary, please have the professional
24

staff to complete.
Check the rotating direction of the cooling fan in case that the cooling fan rotates
conversely and burns the motor.
Please power off the electrical control cabinet for safety purpose if the equipment is
repaired or left idle.
The attached Electric schematic and connection diagram are for reference only. Please
follow the electric drawing along with the machine or contact our eledtrical engineer.

25

26

()
Figure 2 Rotating Ash Cooler Outside Drawing

te
ln
i
h
sA

Ash
inlet section

Supper roll Driving base Driven sprocket

Barrel assembly

t
e
l
t
u
o
t
n
a
l
o
o
C

t
e
l
n
i
t
n
a
l
o
o
C

Driving mechanism
Flexible metal tube
Support ring Axial guide rollers
Outlet section

Rotary joint

Effluenthooper

Support base

27

t
e
l
t
u
o
h
s
A


Figure 3 Diagram on Rotary Joint and water pipe

Coolant inlet

Glands
Packing

Pressure gauge

Pressure gauge valve

Coolant outlet
Glands
Packing

Elbow
inner joint

Needle valve

28

29