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ELECTROSTATIC PRECIPITATOR MANUAL

V T CORP PVT LTD.


GAS CLEANING PLANT





OPERATION & MAINTENANCE
MANUAL

ELECTROSTATIC PRECIPITATOR




ELECTROSTATIC PRECIPITATOR MANUAL 1
V T CORP PVT LTD.
GAS CLEANING PLANT
PROJECT:
ELECTROSTATIC PRECIPITATOR MANUAL
FOR 190 TPH CFBC BOILER


CLIENT:
M/s. ThyssenKrupp Industries India Pvt. Ltd.,
Pimpri,
Pune 400 018
Tel.: (D) 020 6612 4012
Fax : 020 27425611













ELECTROSTATIC PRECIPITATOR MANUAL 2
V T CORP PVT LTD.
GAS CLEANING PLANT


CONTENTS

1. GENERAL INFORMATION

1.1 VT CORP Job No.
1.2 Application
1.3 Plant Site

2. TECHNICAL DATA

2.1 Design Data
2.2 Size and Type
2.3 Electrodes and Rapping Systems
2.4 Drawings

3. METHOD OF OPERATION
3.1 Definition of Term
3.2 Principle of Process
3.3 Diagrammatic Drawing

4. STRUCTURAL DESIGN
4.1 Substructure
4.2 Precipitator Casing
4.2.1 Dust Hopper with level indicator
4.3 Inlet/Outlet Connections and Gas Distribution Elements
4.4 Gas Ducts, Gas Piping
4.5 Internal Equipment
4.5.1 Collecting System
4.5.1.1 Collecting Electrodes
4.5.1.2 Suspension
4.5.1.3 Rapping Bars
4.5.1.4 Rapping System

4.5.2 Discharge System
4.5.2.1 Discharge Electrodes & Discharge Frames
4.5.2.2 Suspension
4.5.2.3 Rapping System
4.5.2.4 Purge Air
4.5.2.5 Insulator Heating System

4.5.3 General Arrangement Drawing


ELECTROSTATIC PRECIPITATOR MANUAL 3
V T CORP PVT LTD.
GAS CLEANING PLANT



CONTENTS

5.0 OPERATION

5.1 Start- Up
5.2 Shut down
5.3 Periodic Inspections
5.4 Fault Detection in case of Failure

6.0 MAINTENANCE

6.1 Preventive Safety Measures
6.2 Daily Maintenance
6.3 Major Inspection
6.4 Spare Parts
6.5 Spare Parts List
6.6 Wearing Parts
6.7 Guide Bush of Suspension Tube
6.8 Pin Insulator for Discharge Electrode
Rapping System
6.9 Hammer Shaft Bearing for Discharge Electrode
Rapping System
6.10 Hammer Discharge Electrode Rapping System
6.11 Cam Operated Hammer Release Device for
Discharge Electrode Rapping System
6.12 Stuffing -Box on Drive for Collecting Electrode
Rapping System
6.13 Hammer Shaft Bearing for Collecting Electrode
Rapping System
6.14 Hammer for Collecting Electrode Rapping System
6.15 Geared Motors for Rapping Mechanisms
6.16 Hold back device for Geared Motor
6.17 Access Door

ELECTROSTATIC PRECIPITATOR MANUAL 4
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GAS CLEANING PLANT






1. GENERAL INFORMATION


1.1 Purchase Order No.:-

Purchase Order No. : 2500002299 DTD. 17.03.10 for Electrostatic Precipitator
for 190 TPH CFBC Boiler
(Please state this number in your correspondence and particularly in your enquiries and
purchase orders for spares.)

1.2 Application:-

The electrostatic precipitator plant cleans the waste gas from CFBC Boiler.

1.3 Plant Site:-

Bajaj Energy Private Limited
A/c Bajaj Infrastructure Development Company Ltd.
Village-Berkhera, Post-Berkhera,
Block-Berkhera, Tehsil-Bisalpur,
District-Pilibhit, , State Uttar Pradesh


Note

This description and manual refers mainly to the mechanical part of the ESP.
The electrical part of the Electrostatic precipitator is given separately.







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V T CORP PVT LTD.
GAS CLEANING PLANT


2. TECHNICAL DATA

2.1 Design Data
Imported Coal Indian coal Design
100 % BMCR 100% BMCR


2.1.1 Operating Volume (Am
3
/Hr) : 313700 315720 360000
2.1.2 Gas Temperature (Deg C) : 147 147 160
2.1.3 Inlet Dust Burden (g/Nm
3
)

: 50 85 100
2.1.4 Outlet Emission. (mg/Nm
3
) :
With all fields working < 70 < 70 Approx 120
With one field out of service 100 100 Approx 195
2.1.5 Overall Collection Efficiency (%) : 99.86 99.92 Approx 99.88
With all fields working


2.2 Size and Type

2.2.1 Size of Electrostatic Precipitators : 23 / 12.5 / 4 x 11 / 400
2.2.2 No. of ESPs. : TWO
2.2.3 Construction
Casing Material : M.S.
Internal Equipment Material : M.S.
2.2.4 Number of Fields per Precipitator : FOUR
2.2.5 Active height of Electrostatic Field (m) : 12.95
2.2.6 Active length of Electrostatic Field (m) : 21.12
2.2.7 Number of Collecting Electrodes (CE) arranged in : 11
Succession in each Field
2.2.8 Number of Passages : 23
2.2.9 Passage width (mm) : 400
2.2.10 Heating
Support Insulators : ELECTRICALLY HEATED
Electrically Heated Hopper Heaters : -----
Heater rating : 0.8kW/Insulator
TR Set Rating : 110kVP/1000mA









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V T CORP PVT LTD.
GAS CLEANING PLANT



2.3 Electrodes and Rapping Systems

Electrodes
2.3.1 Collecting Electrodes (CE) : VT-240
2.3.2 Discharge Electrodes (DE) :
2.3.3 Electrostatic Field 1 : Type-Emitron 15
2.3.4 Electrostatic Field 2 : Type-Emitron- 15
2.3.5 Electrostatic Field 3 : Type-Emitron- 15
2.3.6 Electrostatic Field 4 : Type-Emitron- 0


Rapping Systems:

2.3.7 Collecting Electrodes : Tumbling Hammers mounted on
shafts
Number per Field : 1 Set
TOTAL : 4 Sets

2.3.8 Discharge Electrodes : Impact Hammer activated by cam
Release device.
Number per Electrostatic Field : 2 Sets
TOTAL : 8 Sets

2.3.9 Gas Distribution Plates : Tumbling Hammer mounted on
shaft.
Number per Electrostatic Precipitator : 2 Sets
TOTAL : 2 Sets

2.4 Drawings

Following drawings are attached in the annexure:

2.4.1 ESP General Arrangement : VTC-A1-12500-101
2.4.2 Internal Assembly Drawing (Typical) : VTC-780-001











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V T CORP PVT LTD.
GAS CLEANING PLANT






3. METHOD OF OPERATION

3.1 Definition of Terms

3.1.1 The electrostatic Precipitator Plant is an electrical system for the
separation of solid and liquid suspended particles from gases and
Vapours under the effect of electric fields. In detail the plant
consists of;

3.1.1.1 Transformer Rectifier Set with
3.1.1.1.1 Low voltage section with the equipment for connection and
disconnection of the plant and for adjusting, controlling, regulating,
limiting and Supervising of current and Voltage.

3.1.1.1.2 High voltage section with the equipment for voltage
transformation (transforming and rectifying)

3.1.1.2 High voltage switch gear

3.1.1.3 High voltage supply (cable or bus bar arrangement)

3.1.1.4 Electrostatic Precipitator

3.1.2 The electrostatic precipitator is a part of the precipitator plant in
which the suspended particles are electrically charged and then
separated. It consists mainly of the precipitator casing with the
builtin electrode systems, the internal equipment. The internal
equipment is sub-divided into Electrostatic Fields Designating the area
of a separately disconnectable group of electrodes within one
precipitator casing.

3.1.2.1. The collecting system, including mainly the built in collecting
electrodes on to which the suspended particles precipitate. The
discharge system, comprises mainly of the high voltage carrying
discharge electrodes within the precipitator casing.




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V T CORP PVT LTD.
GAS CLEANING PLANT






3.2 Principle of Process

The gas to be cleaned passes through the precipitator casing, the internal equipment of
which consists mainly of the high voltage carrying discharge electrodes (DE) negative
pole and the earthed collecting electrodes (CE) positive pole which are arranged
opposite the discharge electrodes.

As the discharge electrodes are on high-voltage direct current, the gas molecules are
ionized with the result that a negative corona discharge is created. The dust and mist
particles suspended in the gas are electrically charged by the absorption of negatively
charged gas ions. The charged dust or mist particles are attracted by the earthed collecting
electrodes under the effects of the electrostatic field prevailing simultaneously between
discharge and collecting electrodes. The particles are separated from the gas flow at the
collecting electrodes.

This precipitated dust is periodically dislodged from the collecting electrodes by means of
rapping systems with hammers. It drops into the collecting hopper and is extracted by dust
discharge equipments.

The rapping cycles can be adjusted depending on the adhesive properties of the dust by
means of timers.

3.3 Diagrammatic Drawing

The following worksheets contain schematic representations of a dry electrostatic
precipitator in horizontal design (horizontal gas flow). The worksheet states all essential
parts mentioned in the description of the precipitator.

The high voltage carrying elements must be earthed in accordance with the safety
instructions (see article 6.1) prior to entering the plant.

The worksheets contain detailed representations of the individual design elements.









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V T CORP PVT LTD.
GAS CLEANING PLANT






4. STRUCTURAL DESIGN

4.1 Substructure

In addition to the vertical loads the supporting structure takes up the horizontal forces
allowing at the same time for thermal expansion of the casing.

Pendulum structure columns allow for an expansion of the casing in all direction with
horizontal forces from the thermal expansion and wind loads being transferred via the
bracing members. The fixed-point for the electrostatic precipitator casing is established by
appropriate placement of the bracing at the desired point. (Sketch No: VTC-016-01)

4.2 Precipitator Casing

The precipitator casing forms the enclosed space accommodating the internal equipment
required for dust separation. The casing is designed for the temperature and the gas
pressure stated under 2.1. The VT Corp warranty given for materials does not cover
damages done to parts of the internal equipment as a consequence of exceeding these
values. In case of the ESPs with concrete wall casing VT Corp do not assume any
responsibility. The contractual conditions will take priority.

The loads resulting from dead weight, internal equipment, gas pressure (static), wind and
dust will via the roof beams and the columns be led into the columns of the side walls and
from there into the substructure.

At the beginning and at the end of each electrostatic field and between the electrostatic
fields the top ends of the columns are loaded by the horizontal box-type roof beams which
are arranged across the direction of the gas flow. These roof beams are loaded by their
dead weight, by the weight of the internal equipment including dust, as well as by the
dead weight and the load of the negative pressure borne from the covering between the
roof beams above the electrostatic fields. The covering consists of a gas-tight cover and a
walkthrough rainproof covering arranged on top of it. In the area of the electrostatic fields
the side walls are welded gas-tight between the columns.







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V T CORP PVT LTD.
GAS CLEANING PLANT









For installations with explosion hazards the gas-tight cover, which is normally welded in,
is constructed as a safety cover. Under sudden increase of pressure (deflagration) the cover
is providing for pressure relief.

Prominently displayed and clearly arranged safety signs must be provided by the operator
to warn that the access to the precipitator plant during operation is prohibited and
dangerous to life.

Towards the bottom the casing is closed by the collecting hoppers (pyramid or trough
hopper) with the dust extracting devices mounted at their tips. If necessary the dust

Hopper tips are heated either electrically, by steam or hot water, to avoid that the dew
point in the hoppers falls under the desired value and can lead to dust accretions.

The casing as well as the Inlet/Outlet cones must be provided with a thermal insulation.

Internal catwalks underneath each roof beam are arranged across the direction of the gas
flow at the bottom level of the electrostatic fields. These walkways give access to the
interior of the electrostatic precipitator.

Partition walls and gas baffle plates are installed beneath the electrostatic fields in order to
prevent undesirable streams of unclean gas sneaking to the hoppers.

The access doors are placed in one of the side walls and in the hoppers. The roof beam is
fitted with manholes. Prior to opening a door or manhole all safety measures must be taken
in accordance with Article 6.1.

The structural design of the precipitator permits dust filling up to the top edge of the
hopper.

If the high voltage supply of one or several fields fail due to short circuit, find the source of
trouble without delay. If excessive hopper filling is found to be the source of trouble, the
precipitator installation has already been overcharged. Interrupt the gas volume flow
through the precipitator and empty the hoppers as soon as possible.

Attention is being drawn to the fact that depending on the dust composition, up to 50% of
the dust can be separated in the precipitator even while the high voltage is disconnected.
4. STRUCTURAL DESIGN
VTC-016-01
In addition t o the vertical loads the supporting structure takes up the
horizontal forces allowing ' at the sa'me time for thermal expansion
sf the casing.
Pzndulum structure columns allow for arl expansion of the casing in .
all directions with horizontal forces from the thermal expansion and
wind load being transferred via the bracing members.
The fixedpoint for the eiectrostatic precipitator casing is established
by appropriate placement of the bracings at the desired point.

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V T CORP PVT LTD.
GAS CLEANING PLANT





4.2.1 Dust hopper with level indicator

For static dimensioning, the electrostatic precipitator casing has been calculated on the
basis of a hopper dust charge corresponding to the total hopper volume.

In order to avoid overfilling which would lead to a surpassing of the allowable hopper load
resulting from the dust weight during operation of the electrostatic precipitator unit, each
hopper is equipped with a level indicator, arranged at about 2/3
rds
of the total hopper
height, measured from the hopper outlet flange. As soon as the separated dust reaches this
level, an alarm signal is given. Once the signal is released, the hoppers should be emptied
as quickly as possible.

Should the alarm signal persist in spite of the continuous extraction of the dust and if a
further rise of the hopper filling level is to be expected, the electrostatic precipitator has to
be cut off from the gas flow by means of gates and/or the precipitator unit has to be
stopped.

It is not recommended to continue the precipitator operation disregarding the alarm signal
as this may lead to failure of the structure due to excessive dust loads.

For electrostatic precipitators incorporating several collecting fields it should be noted that
about 80% of the total dust volume is collected in the first electrostatic field. This means
that within a relatively short time after signaling, the hoppers underneath the first
precipitator field may be filled up to the hopper top. Further rising of the dust level up to
the electrostatic field will cause a short circuit; in this case, however, the allowable load has
already been exceeded and a failure of the structure may be anticipated.

It is pointed out that even when shutting down the high-voltage, a dust collection of up to
50% may take place depending on the dust composition and grain size, leading to a raising
of the dust filling level beyond the allowable value.











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V T CORP PVT LTD.
GAS CLEANING PLANT




4.3 Inlet/Outlet Connections and Gas Distribution Elements

On the front wall the Inlet connection is connected to the precipitator inlet and on the rear
wall the Outlet Connection to the precipitator outlet.

In order to reach a uniform distribution of the gas stream the precipitator inlet is fitted with
special gas distribution plates. In case of adhesive dust these plates will be periodically
cleaned by means of rapping devices. The design of these rapping devices including drive
is the same as that of the rapping mechanism for the collecting electrodes. As regards
operation and maintenance, the instructions given for the collecting electrode rapping
mechanism will apply here too.

4.4 Gas Ducts, Gas Pipings

Before and after the electrostatic precipitator the gas is led in the gas ducts. Gas baffles can
be installed in elbows and flared sections of the Inlet duct.

The ducts are designed in such a way that if the dust is dry, no deposits can be formed. As
a general rule such points where moist dust would have to be sucked off are not connected
to the duct system. The gas velocities in the ducting are set at such values that wear is kept
within reasonable limits.

If necessary, the ducts must be provided with a thermal insulation.

Thermal expansions can be absorbed by Expansion Joints. The arrangement of the
measuring points is most important for dust load measurements. At the measuring point
location velocity and dust should be distributed as uniformly as possible. It is desirable to
have a gas velocity of at least five meters per second in order to ensure maximum
measuring accuracy. The measuring points in the raw and clean gas should be situated as
near as possible to the dust collection equipment allowing for appropriate stretches for
inlet and outlet which must not contain any elements which might influence the gas flow,
as for example gate valves, branches, elbows, changes of cross-section, baffles etc.




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V T CORP PVT LTD.
GAS CLEANING PLANT



4.5 Internal Equipment

4.5.1 Collecting System

The collecting system consists of collecting electrodes arranged at passage distance parallel
to the gas flow, including suspension and rapping bars with associated Tumbling Hammer
rapping system.

4.5.1.1 Collecting Electrodes

The individual collecting electrodes, also called plates, consists of cold-rolled special metal
plate profiles. At the upper end of each plate two suspension plates are fastened and
suspended from the carrier beam by means of bolts.

4.5.1.2 Suspension

Each suspension consists of a standard I beam with U-cleats welded to its bottom. Each
Ibeam carry one row of sequence-connected collecting electrodes of one electrostatic field.
The two ends of each carrier-beam are so bolted to the roof beams that a fix-point is formed
at the rapped side whereas the opposite side is capable of absorbing thermal expansions.

4.5.1.3 Rapping Bars

At their bottom end, the collecting electrodes of one row are connected to a rapping bar by
special bolting. Each rapping bar, consisting of two parallel flat bars welded to anvils at
one end and holding a spacer at the other end, is kept at passage distance at the Internal
walkways of the casing. The electrodes with rapping bars can freely move downwards. In
addition to the task of keeping the various electrode rows at passage distance, the rapping
bars serve the primary purpose of transmitting the rapping blows, delivered to the anvil
tips, to the tightly attached electrodes and to vibrate them in this manner to remove the
precipitated dust.

4.5.1.4 Rapping System

Each electrostatic field has a Tumbling hammer rapping mechanism with hammers
assigned to the individual collecting electrode rows. These free falling hammers are
mounted onto the hammer shafts at passage distance in the precipitator interior and are so
staggered that they drop successively onto the anvils of the rapping bars for periodic
vibration and cleaning of the respective rows of collecting electrodes.


COLLECTING ELECTRODE SYSTEM
COLLECTING ELECTRODES (VT-240)
ITE EMITITNG ELECTRODES (EiviITRON-15)
-
VTC-008-0 I
1
COLLECTING ELECTIZODE SYSTEM
I V T COY^
1 COLLECTING ELECTRODE (VT-'240)
-I EXAG
BOLT

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GAS CLEANING PLANT





The hammer shafts are supported on roller bearings which are mounted to the Internal
Walkways arranged across the gas flow inside the electrostatic precipitator. The hammer
shaft bushings through the side wall of the casing are sealed off by stuffing boxes. The
drive is supplied by one geared motor for each rapping mechanism. This geared motor,
which is equipped with a hold-back device, is supported outside the casing on a bracket
which is mounted to the casing wall. The geared motor is connected to the hammer shaft
by means of a disc coupling with radial clearance.

The rapping cycles can be varied and controlled by connection of a timer (rapping cycle
control). The rapping cycle control is adjusted by VT Corp start-up personnel. In case of
operational contaminations of the electrostatic precipitator at a later date, a correction of
this setting may possibly be required in order to achieve an optimum adaptation to the
latest operating conditions which may differ from those prevailing at the start-up time.

4.5.2 Discharge System

The discharge system consists of discharge frames which are suspended in the passage
centre and are equipped with discharge electrodes. The frames are suspended from the
casing by means of brackets, support frames and suspension tubes as well as support
insulators. The latter are arranged within the box type roof beam.

In order to prevent flash-overs at the side of the insulators which faces the gas an
adjustable quantity of air is sucked through the insulator if negative pressure prevails in
the electrostatic precipitator or is forced through the insulators by means of a purge air fan
in case of positive pressure. The formation of moisture can be prevented by an electrical
insulator heating device. The discharge electrodes are cleaned by means of a rapping
system.

4.5.2.1 Discharge Electrodes and Discharge Frames

The discharge frames holding the discharge electrodes are suspended in the centre of the
passages formed by the parallel rows of collecting plates. The discharge frames consists of
pipes welded together in a grid type arrangement. The horizontal pipes have holes to
accommodate the discharge electrodes.

The discharge electrodes type EMITRON-15 or EMITRON-0 consist of flat strips with sharp
edges and spikes which are welded across in a symmetrical distance over the length of
strip.

Both angle shaped ends of each strip carry spot welded studs. By means of these studs the
discharge electrodes are fitted into the holes of the discharge frame pipes in such a manner
that they are taut and point with their spikes into the collecting pockets of the collecting
electrodes.

EMITTING
ELECTRODE I I
(EMITRON- 15)
f
EMITTING
ELECTRODE
FRAME
EMITrING
ELECTRODE
(EMITRON - 1 5)

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GAS CLEANING PLANT





4.5.2.2 Suspension

The discharge frames are held by two carrier brackets which are bolted to the outermost
vertical pipes of the discharge frame tops. These frames are suspended in the middle of the
passages where each of them is kept at place by two Distance Brackets which are bolted to
the outermost vertical pipes of the discharge frame bottoms.

The carrier brackets and the distance brackets are connected to the support frames hanging
across the direction of the gas flow in front and behind the zones. The support frames
consist of connected rolled sections. One support frame is used for upto 50 passages (seen
in direction of the gas flow).

Each support frame is suspended by suspension tubes from support insulators installed in
the roof beam. Thus the support insulators transfer the loads of the discharge system to the
roof beams and provide at the same time for the electrical isolation between the high
voltage carrying discharge system and the earthed casing.

4.5.2.3 Rapping System

The discharge electrode rapping system consists of cam operated hammer release device
with drive, Pin insulator, lower tie-rod and hammer shaft with hammers and hammer shaft
bearings.

The rotating cam, by way of the rollers of the release element, raises the lifting element
which disengages at the upper limit of travel. The hammer shaft and hence the hammers
are actuated via the connected Pin Insulator, lower rod and Lever. The hammers are thus
lift up and fall back to their original position when released. If hammer shafts are arranged
above each other they are operated by one drive and interconnected by connecting rods.
The cam operated hammer release device permits an infinitely variable adjustment of the
hammer lift.

Each discharge frame with attached discharge electrodes is rapped by a hammer. The
hammers of one rapping mechanism are attached to a hammer shaft which, supported in
cast iron pedestal bearings, runs across the direction of the gas flow. The hammers strike
onto the anvils which are securely fixed on the discharge frame to ensure a satisfactory
transmission of the rapping blows.





HAMMEI?
-COLLECTINS ELECTRODE
- TUMBLING HAMMER
--
RAPPING BAR

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4.5.2.4 Purge Air

In order to keep the inside of the support insulators which support the discharge system
free from dust accretions it is necessary during the operation of the plant to have a weak
flow of air within the insulator itself and in the subsequent protection pipe with the air
always flowing downwards from the cap of the insulator to the interior of the precipitator.
For this purpose each insulator cap has 12 bore holes which can be closed by means of
rivets. In order to regulate the required rate of sucked in purge air the VT Corp start-up
crew will open a corresponding number of these purge air bores by removing the rivets. It
may be that in plants operating at very high negative pressures all bores remain closed and
the required quantity of purge air is sucked in through the not perfectly sealed bores.
Normally the scavenging air is heated up sufficiently to the temperature prevailing in the
roof beam so that the temperature is kept at or above dew point level. In special cases
where there is a heavy corrosion risk it may be necessary to heat up the sucked in air at the
roof beam inlet.

In plants where the precipitator does not constantly operate under negative pressure it is
necessary to install a purge fan which forces the required quantity of purge air into the roof
beams. This air is distributed to the different roof beams via a piping system.

4.5.2.5 Insulator Heating System

In order the avoid temperature fall below dew point level at the support insulators and
consequently to prevent the formation of condensate which could cause electrical
flashovers, the support insulators will be electrically heated whenever this is necessary.
This insulator heating can be most important during plant start-up (allow for sufficient
pre-heating time!) as well as during part-time stoppages (unless otherwise specified the
heating must be continued during the stoppage)

The heaters are arranged round the circular bases which carry the support insulators. In
order to ensure that the heat is radiated as far as possible towards the interior of the
insulators, each insulator base is fitted with a removable insulating jacket.

4.5.3 General Arrangement Drawing

The general arrangement drawing of the internal equipment which is included in the annex
applies to the precipitator size stated under Article 2.2.




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GAS CLEANING PLANT






5. OPERATION
5.1 Start up
The operation of a precipitator plant is defined as the manipulations required for start-up
and shut-down and the periodical inspections which are necessary during plant operation.
The following inspections shall be carried out before start-up:
Maintenance and/or repair work must be completed and all tools and implements must
be removed. There must be no person or foreign matter inside the plant.

5.1.1 There must be no interfering dust accumulations, accretions or condensates.

5.1.2 In plants designed for exhaust of dust laden air all hoods enclosing dust sources
must be as tight sealing as possible.

5.1.3 All doors and cleaning parts must be closed.

5.1.4 Any explosion relief valves or foils, if any, must be in proper condition.

5.1.5 The dust discharge and subsequent dust conveying element or collecting hoppers
must be dustproof and in proper condition (it is advised to effect a trial run).
5.1.6 All measuring and control instruments must be in working condition.

5.1.7 The thermal insulation, if any, must be in proper condition.

5.1.8 It is necessary that the electrostatic precipitator must be adequately pre-heated.

5.1.9 The plant must be properly earthed.

5.1.10 The transformer rectifier set must be in proper condition.

5.1.11 After repairs, overhauling work, inspections etc. the direction of rotation of drives as
well as the proper condition of the protective devices must be checked. Special
attention must be paid to the hammers of the collecting electrode rapping
mechanisms; all of them have to be in the position corresponding to the normal
function of the hammer shaft which means that no Hammer Assemblies must be
dropped prematurely by hand as this may cause deformations by jamming the
hammers against the rapping bars when the rapping mechanism starts up again.




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GAS CLEANING PLANT




The Start-up shall be carried out in the following order:

5.1.12 Inform control centre

5.1.13 Connect insulator heating system about 6 hours before connecting the transformer
rectifier set, before admitting raw gas into the precipitator. After the electrostatic
precipitator has been heated up to 150-1800C to operating temperature. The
insulator heating system may be disconnected if there is no thermostatic control.

5.1.14 Connect hopper tip heating system about 4 hours before connecting the transformer
rectifier set, before admitting raw gas into the precipitator.

5.1.15 Connect purge air fan and purge air heating system.

5.1.16 Start rapping mechanism. Re-set the clock of the rapping cycle control mechanism (if
any) to the values that had been set before shutdown if rapping has been continuous
during the start up period.

5.1.17 Start dust discharge and dust conveying elements.

5.1.18 Open shut off Dampers.

5.1.19 Depending on operating conditions: Start fan, Connect transformer rectifier set
when a gas temperature of 150-180
0
C after the electrostatic precipitator has been
reached.

5.2 Shut - Down

The shut-down shall be carried out in the following order:

5.2.1 Inform control centre.

5.2.2 Depending on operating conditions : Switch off the ID fan, close shut-off elements,
disconnect transformer rectifier set if no more dust is expected and secure against
unauthorized re-connection (hang up safety signs). Observe safety measures.
Or
Disconnect transformer rectifier set if no more dust is expected and secure against
unauthorized re-connection (hang up safety signs). Observe safety measures.
Disconnect ID fan.

5.2.3 Close shut off Dampers.


ELECTROSTATIC PRECIPITATOR MANUAL 19
V T CORP PVT LTD.
GAS CLEANING PLANT





5.2.4 The dust discharge and dust conveying elements must remain in operation until
there are no more dust accumulations in the hopper of the dust collection plant and
the hoppers as well as the dust discharge and dust conveying elements are
completely empty. The same applies for the hopper tip heating system, if any.

5.2.5 The rapping system should be kept in operation during short time shut-downs. In
case of prolonged shut downs continue to operate the collecting electrode rappers
after shut down of the installation to be de-dusted until the entire precipitator
plant is cooled down to ambient temperature. This is to prevent damages to rapping
bars and collecting electrodes. The rapping cycle control mechanism, if any, must be
set for continuous rapping. For short shut downs switch on insulator heating
system, if any, (this will not be necessary in the case of heating systems with
thermostatic control) or leave it switched on if it is set for continuous operation.
During prolonged shut downs the insulator heating system may be switched off.

5.3 Periodic Inspections

In order to ensure a trouble free operation of the plant and to prevent damages, it is
necessary to carry out periodic inspections of the entire plant i.e. of its most
important values and of the function of the dust collection plant proper.

The periodic inspections of the dust collection plant cover:

5.3.1 Temperature

For reason of the material properties the maximum temperature as per 2.1 must not be
exceeded. On the other hand the gas temperature must not fall below dew point level
because of the risk of corrosion. Gas temperatures or temperature ranges stated in the VT
Corp order confirmation and stated as necessary for the proper operation of the plant must
be strictly maintained. It is advisable to measure the temperature ahead of the precipitator
inlet.

5.3.2 Dust Discharge
A continuous control of the operability of dust discharge and dust conveying elements is
necessary to prevent dangerous dust accumulation and congestions which might damage
the electrostatic precipitator. Especially in case of high negative pressures it is
recommended to carry out air tightness tests which will prevent undesired corrosion
through air-in leakages. The same applies to all flange connections and inspection openings
on gas ducts.

ELECTROSTATIC PRECIPITATOR MANUAL 20
V T CORP PVT LTD.
GAS CLEANING PLANT




5.3.3 Electric Measuring Instruments

The function of the high voltage installation should be observed as described in the
pertinent maintenance instructions which will be helpful for ready detection of operational
irregularities. Also, the electrical measuring instruments for motors, Purge air fans, heating
systems etc. must be observed closely. Visual inspection of driving motors is
recommended.

5.3.4 Visual Evaluation of Stack

It may be necessary to carry out exact measurements of the dust content if the plume is
bad.

5.3.5 Pressure relief facilities

Safety systems which prevent inadmissibly high pressures from being built up in the
interior or protective systems, if any, which provide for pressure relief, have to be checked
carefully and regularly. Leakages (air-in leakage) increase the danger. Leakages can often
be ascertained through pressure or temperature changes. Approaches to the installation
must be kept clear all times.

5.4 Fault Detection in case of Failure

5.4.1 Electrical Failures

5.4.1.1 Isolate the electrostatic precipitator from the transformer rectifier set by means of an
isolating switch. Connect switch panel. Increase and decrease voltage. If this is not
possible, change electronic draw-out units. If it is still not possible to make the
circuit, trace fault with the help of the wiring diagrams.

5.4.1.2 If the cause of failure is in the high voltage system switch the dead electrostatic
field temporarily to the second high voltage set with which most plants are
equipped.

5.4.1.3 If the transformer rectifier set is in order; the next step is to check the high voltage
cable. Remove the connection between the cable-sealing-terminal and support
insulator at the precipitator (roof beam). Increase voltage manually.

The corresponding safety regulations must always be observed.





ELECTROSTATIC PRECIPITATOR MANUAL 21
V T CORP PVT LTD.
GAS CLEANING PLANT






5.4.2 Mechanical Failures

If during fault tracing operations it is necessary to enter the electrostatic precipitator
itself or to work near high voltage carrying elements; the plant must be made dead
before starting work. It must be ensured that this dead state is kept.

5.4.2.1 Inspection of dust hoppers and dust discharge equipments. Due to dust bridges in
the hopper outlet, dust could built up and reach up into the electrostatic fields thus
leading to short circuits.

5.4.2.2 Inspect insulators for cracks and excessive contamination. If an excessive
accumulation of dust which could lead to flash overs is found, the insulators must
be cleaned with the help of the dry cloth.

Broken support insulators must be replaced. The possibility of replacing damaged
support insulators without having to enter the precipitator interior is shown in
Sketch. Openings for this purpose have been provided at certain points in the roof
beam bottom plate which are closed by bolted plate covers and gaskets.

The suspension Hook shown in sketch and the necessary brackets must be
fabricated according to the dimension specified. For this purpose, the discharge
system must be supported within the precipitator, for example by suspending the
suspension beam of the support frame by means of a hoist to a hook or an eyebolt to
be welded on to the roof beam-top-plate or by supporting this suspension beam on
brackets to be welded to the side walls of the precipitator. When a tie-rod of a
discharge electrode rapping mechanism has been passed through the damaged
support insulator disengage this tie-rod.

For dismounting the cap, the gaskets and the damaged insulator both nuts of the
suspension tube have to be removed. During this operation the suspension tube
must be held fast to keep it from dropping into the precipitator. Before loosening the
suspension tube unscrew the cap or capscrew for the guide sleeve from the
suspension tube.

When mounting a new insulator use new gaskets and new cord (do not press in).
After re-assembly of the entire support insulator in reversed order the discharge
system must be re-adjusted (see under 6.3.5). In case of frequent breaks of insulators
check the performance of the heating system or consider the installation of the
heating system (see under 4.5.2.5).

If a pin insulator belonging to the discharge electrode rapping mechanism is found
to be broken, check whether there is a rapper failure (this might be a blocking or
another kind of defect, even inside the precipitator). Replacement of the insulator as
per sketch No. VTC-010-01
T COYPA SUPl'i3R'r INSULATOR ARRANGEMENT
VTC- - 010- 01
- REPLACEMENT OF SUPPORT INSUL,\TOR I
Determine and record
dime~sion "A" remove
(cap
Attention :
While working, ensure that
no items drop i n t ~ precipitator
interior.
Hang Support hook into
support frame and faste
in channel support
Separate lower tis-rod
from pin insulator and
remove cap. Take pin
insulgtor aside and rem
support insulator
lnsert new support
Insert new gaskets.
cap, pin insulator a
tie-rod, remove support
hook.
Close opening.
Check dimension "A",
readjust by two nuts
of suspension tube, d-a--, '
if necessary.

ELECTROSTATIC PRECIPITATOR MANUAL 22
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GAS CLEANING PLANT






5.4.2.3 Inspect geared motors for proper drive of rapping mechanisms. If a motor fails to
start check first whether the fault is at the electrical connection. If the motor winding
is found to be burnt out the only remedy is to replace the entire geared motor. It is
absolutely necessary to find out the cause of this failure. (For this purpose check
rapping system and try to find out whether there is a possibility of moisture
entering the winding).

5.4.2.4 If the failure is not among the types described above the electrostatic precipitator
must be checked during a shut-down with regard to possible short circuits. Cut out
broken discharge electrodes. The absence of a number of discharge electrodes will
not essentially influence the collection efficiency. Furthermore, check all wearing
parts as per 6.5. Particular attention should be paid to rapping mechanisms.



ELECTROSTATIC PRECIPITATOR MANUAL 23
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GAS CLEANING PLANT




6. MAINTENANCE

The maintenance of a dust collection plant is of utmost importance. The following
quotations from the technical literature will stress this point:

Each dust collection plant must be properly operated and serviced so that it can always
fulfill its purpose

It is a known fact that the collection efficiency of a dust collector may decrease
considerably as the time passes, if the dust collection plant is not periodically and properly
serviced.

All dust collection plants require systematic servicing if they are to fulfill their task for a
long time. This maintenance has been automated on a small scale only which means that
human operators are required for plant supervision.

Maintenance work is sub-divided into daily maintenance and maintenance operations
which have to be carried out within the limits of the main inspections which will have to
take place at longer intervals.

6.1 Preventive Safety Measures

Before any work is carried out on the plant, all safety precautions must be taken under
observance of the prevailing local rules and regulations. The plant must be completely
disconnected and secured against connection of the high voltage and all moving parts.
(Move main switch into off position, remove main fuses). A warning sign is not sufficient
in this case. All plant elements which carry current under operation must be visibly
earthed. When working within the precipitator an earth connection must be made at the
working area.

Before entering the electrostatic precipitator each of the electrostatic fields must be
individually earthed. For prolonged repair periods separate the high voltage cable from the
precipitators. In order to prevent accidents the dust producing plants must be also shut-
down or isolated against the electrostatic Precipitator. Make sure that the fan cannot be re-
connected. The person or office responsible for plant supervision must be notified. Observe
special plant related instructions in case of poisonous or explosive gases.

The precipitator may be entered only if all rotating and moving elements e.g. rapping
mechanism and dust discharge equipments are placed out of operation. Rapping
mechanisms, dust discharge elements may be put into operation during inside inspection
of precipitator only in such cases if these devices are the subject of inspection. When
carrying out this type of inspection care must be taken that nobody can be caught by
running parts.


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V T CORP PVT LTD.
GAS CLEANING PLANT






As a general rule an electrostatic precipitator plant shall be entered only with safety helmet,
safety shoes and protective gloves in order to prevent injuries.

In plants with corrosion or erosion hazards check whether the parts to be stepped on still
have sufficient supporting capacity to carry inspection personnel and whether corroded
parts or corrosion products (e.g. from the side wall or from the roof beam) could possibly
drop down on the inspecting personnel.

6.2 Daily Maintenance

Daily Maintenance of a plant refers to inspections and measures required to maintain the
plant and its measuring and control instruments in operating condition. As far as possible
moving parts should be inspected during operation as such parts require special attention.

The following items are subject to daily inspection:

6.2.1 The fans with drives Observe suppliers special instructions;

6.2.2 The dust discharge equipments with drives Check tightness and proper
operation. Observe lubrication instructions given for these items by the supplier.

6.2.3 The rapping mechanisms Check proper operation of drives, observe lubrication
instructions given for these items; the control, damper and regulating devices; the
high voltage installation; the hoppers and dust chutes by manual probing in case
of hot gas plants and by knocking in case of cold gas plants it is possible to
determine whether hoppers and dust chutes are excessively filled. In such cases
the hoppers and dust chutes must be carefully emptied in order to prevent
overloading of the subsequent dust conveying equipments.

In case of inflammable or explosive mixtures of dust and gas, hoppers and dust chutes
must be opened only under strict observance of the relevant special safety instructions.

Points at which hot or other dusts which could be dangerous in any other way could
escape must not be opened under any circumstances. Opening for the purpose of checking
the dust level is not permitted. Adhering dust must be dislodged from within by means of
stokers after shut-down and cooling of the plant.





ELECTROSTATIC PRECIPITATOR MANUAL 25
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GAS CLEANING PLANT




6.2.4 The fire and explosion protection devices check the latter particularly for their
tightness.

6.2.5 All measuring, indicating and recording instruments e.g. general operability,
level of measuring fluid, changing of recording tapes and recorders, cleaning of
dust-exposed connections and sensors etc.

6.2.6 The shut-off dampers in the gas duct in order to ensure their operability at any
moment they must be trial-operated at regular intervals which result from
practical operation. It is recommended to carry out these operational tests at least
once per month

6.2.7 Tightness of flange connections and inspection openings on gas ducts as well as
the operation of exhaust devices in exhaust installations.

6.3 Major Inspection

Major inspection of a plant refers to thorough inspections carried out at longer intervals
during which the internal equipments also are inspected for wear and corrosion. During
this major inspection it may be necessary to repair or replace such parts that are found to
be damaged or no longer in good working condition.

Major inspections should take place every 6 to 12 month.

A major inspection of the electrostatic precipitator plant for which this operating manual
has been drawn up shall be carried out once a year unless shorter intervals are required
because of particularly adverse operating conditions. The most appropriate time for a
major inspection of the precipitator plant would be the overhauling of the entire plant
which could take place at identical intervals.

The major inspection covers the following points:

6.3.1 Shut-down of plant and earthing according to current regulations. Take all safety
measures as per 6.1.
6.3.2 Check tightness of casing, cover and hoppers and repair damages caused by
corrosion. Check whether the thermal insulation is rainproof.
6.3.3 Heavy dust accretions within the electrostatic precipitator and especially on parts
of the internal equipment must be removed with due care. It is absolutely
necessary to clean the gas distribution plate from any dust deposits. Check dust
hoppers and dust discharge elements for dust pockets and remove dust
accumulations. Thorough cleaning is recommended in any case.





ELECTROSTATIC PRECIPITATOR MANUAL 26
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GAS CLEANING PLANT




6.3.4 Check operability of all rapping mechanisms. This will include the rapping
mechanism for the gas distribution plate, if any.

6.3.5 Check correct passage clearance (space between plate rows across the direction of
the gas flow). In operating condition the discharge frames must be suspended in
the centre of the passage with a tolerance of 15 mm. Re-adjust in case of
deviation
When the discharge frames are suspended in the passage centre in cold condition
it is to be expected that they are centrally suspended also in operating condition.

Small and irregular deviations can be corrected at distance brackets or carrier
brackets. In case of major deviations it must be checked whether the suspension
beam of the support frame is level as it was during initial erection. The necessary
adjustment is made by raising or lowering the suspension tube by way of turning
the top nuts. If these nuts cannot be turned because of excessive friction on their
seat, the suspension tube or the suspension beam of the support frame must be
slightly raised by means of a hoist in order to relieve the nuts.

6.3.6 Inspect discharge electrodes. Cut out broken electrodes if any (the absence of a few
discharge electrodes has no considerable influence upon the collection efficiency).
If possible re-tighten slack discharge electrodes by hand.

6.3.7 The suspension tubes must be suspended perpendicularly and in the centre of the
protection pipes.

6.3.8 All lubrication points in the plant area must be treated according to the
instructions.

6.3.9 All insulators in the roof beam must be cleaned with a dry cloth and checked for
damages. The replacement of a support insulator in the roof beam is described
under 5.4.2. The replacement of a pin insulator of the discharge electrode rapping
mechanism in the roof beam is described under 6.5.2.

6.3.10 Remove dust from apparatus, insulators as well as from any or cable sealing
terminals. Proceed with special care in order to avoid damages (It is recommended
to use a brush or an air pump for cleaning)

6.3.11 Check high voltage switches, switch blades and contacts, if any. Replace worn
parts. Grease or oil the bearing of moving parts.

6.3.12 Check oil levels on rectifiers and refill with transformer oil, if necessary.

6.3.13 Check ventilation system of high voltage room, if any.



ELECTROSTATIC PRECIPITATOR MANUAL 27
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GAS CLEANING PLANT







6.3.14 Check gas ducts and gas pipes for dust deposits. It is of utmost importance to
remove them since they affect the efficiency of dust collection and may cause
damage because of their weight. Further all lines must be checked for corrosion
and wear. Corrosion and wear may considerably impair the static strength thus
leading to repairs. Wear protections must be replaced where necessary.

6.3.15 Check the operation of such plant sections which are connected with the
electrostatic precipitator plant. Check all wearing parts as per instructions given
under 6.5

6.3.16 After completion of all work check carefully whether tools, cleaning rags or other
foreign matter has not been left behind in the precipitator. Pass a light over all
passages with an inspection lamp. Special attention must be paid to the dust
hoppers.

6.3.17 Close all openings and access doors of the electrostatic precipitator plant and fit
them with clearly visible warning signs.

6.3.18 Clear all approaches, stairs and platforms.

6.3.19 As a final measure carry out an electrical test of the precipitator under air and in
cold conditions.

Make sure that nobody is within reach of high voltage carrying parts. This includes also the
electrostatic precipitator.

6.4 Spare parts

Spare parts are parts which are indispensable for the proper functioning of the plant and
are subject to a certain wear or inevitable danger of breaking and which furthermore are
available only from certain suppliers due to their particular material, form, design, delivery
time etc.

These spare parts should always be kept in stock in the prescribed quantity by the plant
management.

The following spare parts list contains those spare parts which the plant management
should keep in stock for an electrostatic precipitator.

Number of parts may vary according to size and number of precipitator plants.





ELECTROSTATIC PRECIPITATOR MANUAL 28
V T CORP PVT LTD.
GAS CLEANING PLANT



6.5 Spare Parts List
Sr. No Description of Items Qty
1. Hammers for GDPRM 1 No
2. Hammers for CERM 4 Nos.
3. Hammers for DERM 4 Nos.
4. Gaskets for support Insulator 3 sets
5. Gaskets for Pin Insulator 1 set
6. Support Insulator 3 Nos.
7. Pin Insulator 2 Nos.
8. Insulator Heaters 3 Sets
9. Geared Motor for DERM 1 No.
10. Geared Motor for CERM/GDPRM 2 Nos.
11. Thermostat 1 No.

6.6 Wearing Parts

Wearing parts are parts which are subject to wear due to mechanical loads and which for
this reason must be serviced within the limits of the major inspections i.e. they must be
inspected and when they have reached the point of critical wear they must be replaced. In
addition to the determination of actual wear it must be estimated whether the point of
critical wear will already be passed before the next major inspection takes place. Also in
this case the replacement must be made. The subsequent description of the various wearing
parts states only the critical wear as a criterion for the necessity for replacement. The
estimation of the wear which will take place before the next major inspection will be made
by the inspection personnel

The number of pieces stated in the following list of wearing parts are based on figures from
past experience. As the wear depends on different factors such as for example dust,
temperature, prevailing gas atmosphere, it may vary from plant to plant.

The following parts must be checked:

6.7 Guide Bush of Suspension Tube, Sketch No.VTC-013-2

The guide bush which consists of a self-lubricating sintered material is inserted into the
upper end of the suspension tube and serves for guiding the upward and downward
motions of the lower tie -rod for the discharge electrode rapping mechanism. To replace the
sleeve remove the upper end of the tie-rod from the lower cap of the connected pin
insulator

Then the box nut which fixes the guide bush in the suspension tube is removed from the
suspension tube so that the loose inserted guide bush can be removed. After insertion of
the new bush reassemble in reversed order.

I
SUPPORT INSLTAr'LTOR OF EhiiTTING SYSTEM V T C -0 13-2
DRIVE FOR EMITTING ELECTP.ODE I?-APPING
h4ECHANISM. AND SUPPORT INSULATOR SYSTEM
VTC-013/014-03
---
1

ELECTROSTATIC PRECIPITATOR MANUAL 29
V T CORP PVT LTD.
GAS CLEANING PLANT





Critical Wear

The bush must be replaced if only about 4 mm of the material is left. This thickness is
measured from the outer edge of the upper bush ring.

6.8 Pin Insulator for Discharge Electrodes Rapping System

The Pin Insulator, as a component of the discharge electrode rapping system, is the
electrically insulating element between earthed cam release device and lower tie-rod on
high voltage. It transmits the lifting force of the cam release device to the lower tie-rod.

Damage due to wear does normally occur at the pin insulator. In an Exceptional case of pin
insulator rupture the clamped-on caps with the welded-on connecting elements can be
clamped onto the new insulator. It is recommended, however, to install a new pin insulator
Complete with attached fittings. This replacement is included in the spare parts lists.

The pin insulator caps are connected to the upper and lower tie-rods by an articulated
arrangement via fork joints spring sleeve and hex, head bolts.

These connections must be disengaged for the replacement of a pin insulator complete with
caps.

6.9 Hammer Shaft Bearing for Discharge Electrode Rapping System
Sketch No.VTC-012-01

A split cast iron pedestal bearing with a 53 mm dia. bore is used as hammer shaft bearing.
It is mounted on the support frame by means of 2 bolts.

Critical Wear:

The hammer shaft bearing, with the shaft always touching only the bottom of the bore
must first be turned by 180
0
if the depth of the wear inroad has reached 10 mm maximum
at this bottom side. Thus the worn side of the bore is brought to the top and the shaft rests
now on the opposite side of the bore which has not been used before. The entire bearing
must be replaced when the maximum admissible wear inroad has reached 10 mm also on
this side.





EMITTING ELECTRODES
FT BE.PJ<ING AND HAMMER
VTC-012-01
~edestcl bearing
-----
.
Centre of
l
.

ELECTROSTATIC PRECIPITATOR MANUAL 30
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6.10 Hammer for Discharge Electrode Rapping System sketch No.VTC-012-02

At its suspension point the hammer is fitted with a sleeve, which is made of a wear-
resistant material, same as the bolt. The hammer is fastened to the hammer shaft by means
of a bolted clip connection. Experience has shown that it is more economic to replace the
entire hammers when the point of critical wear has been reached than to replace wearing
parts inside the precipitator. It is recommended to carry out any overhaul of the
dismounted hammers by mounting a complete new suspension in the workshop.

For replacing the hardened sleeve and the hardened bolt, which is fastened by welded-on
locking plates, the welds at the hammer handles have to be ground off. The new hammer
suspension comprises all the parts except for the hammer which consists of the hammer
head and the riveted-on handle.

The new sleeve with the hardened bolt is then introduced into the hammer handle and the
locking plates are re-welded to the hammer handle for keeping the bolt in place. The
locking plates must point upwards to the end of the hammer handle.

When fitting overhauled or new hammers onto the hammer shaft, care must be taken that
the sleeve is clamped into the two clamps with its slot pointing upwards towards the
hammer shaft, that the fastening points are clean and that the fastening bolt is tightened by
means of the stipulated torque. Then the connection is secured by a tack weld between nut
and bolt.

Critical Wear:

The sleeves and bolts must be replaced if the total wear (wear inroad in sleeve plus wear
inroad in bolt) has reached 2-2,5 mm. To measure the wear, remove one hammer (provided
that wear is equal in all hammers).

6.10 Cam operated hammer release device for discharge electrode rapping system.
Sketch No. VTC-014-01

The cam operated hammer release device is equipped with encapsulated grease-filled ball
bearings at all turning points so that there is practically no detectable wear with the slow
motions occurring during the operation.





Dowel Clam9
--
Hammer shaft Hexagon
7
bolf
UPPER TIE ROD
PIN INSULA'TOR ASSEMBLY \'?ITH:
TIE ROD CONNECTIONS
FORK [ T I
VTC-012-03
M PLATE
CL4MPING RING
( ) \ PACKING
SECIION A-A
-
I WX EQLT
-L---
RIhG SEGMENT
. SPRING WASHER
LOCK NUT
I l l \
\ . '
\ HEX-BOLT
I
I
j
,, GUIDE BUSH
RAPPING OF EMITI'ING ELECTRODES
v T c - 0 1 4 - 0 1
CAM REL,EASE MECrIANISM
-. Upper tie-rqd

ELECTROSTATIC PRECIPITATOR MANUAL 31
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GAS CLEANING PLANT





A function test of the wheel flange rollers for lifting lever guidance and at the rollers which
roll at the cam can only be performed by checking the ease of play by turning manually in
unloaded condition. Relubrication is neither possible nor necessary. The pedestal bearings
of the cam shaft which are also fitted with encapsulated ball bearings can, if necessary, be
relubricated with lithium soap grease with an anti-corrosion additive (possibly also with
lime soap grease). Never use soda grease under any circumstances.

We never experienced so far that any part of a cam operated hammer release device had to
be replaced. Such parts are therefore not included in the wearing parts list. They would
normally be available in exceptional cases of damage to ball bearings, rollers and bearing
bushes from our store.


6.12 Stuffing Box on Drive for Collecting Electrode Rapping System,
Sketch No: VTC-011-02

The stuffing box serves to seal up the hammer shaft at its passage through the casing
wall. The stuffing-box gland must not be tightened too hard against the packing consisting
of sealing cord 10 mm in order to prevent excessive torque losses due to increased
friction.

Critical Wear:

If inspection shows that the packing can no longer provide adequate sealing upon
moderate tightening of the stuffing box gland, the packing must be replaced.

For this purpose both nuts of the stuffing-box gland are detached and removed from the
stuffing-box body. The gland itself remains on the driving shaft. Then the packing can be
replaced and the gland carefully re-tightened.


6.13 Hammer Shaft Bearings for Collecting Electrode Rapping System
Sketch No. VTC-011-03

The hammer shaft of the collecting electrode rapping system which carries the tumbling
hammers rests freely on the bearings arranged on the Internal walkways. Each hammer
shaft section is supported in two or more of these bearings, which are fitted with rollers.
The axial guidance of each hammer shaft section is provided by adjustment rings. The
individual shaft sections are connected by coupling which also take up any thermal
expansions.


ROLLER BEARING
FOR COLL. ELECT. RAPPING MECHANISM
VTC-011-03
- - - -
Hex. bolt
nut and

ELECTROSTATIC PRECIPITATOR MANUAL 32
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GAS CLEANING PLANT





The points threatened by wear have been arranged between the rollers and their bearings
in order to avoid any wear at the shaft which may rotate continuously. The shaft itself rolls
wear-free on the rollers. The hardened rollers are supported on sleeves which are also
hardened and whose slots are to point downward at the bearing block. Rollers and sleeves
can be replaced very easily by loosening the bolt connection.

Critical Wear:

These parts are to be replaced if the total wear inroad into roller and sleeve amounts to
2 2,5 mm. when fitting the bolted joint torque has to be 12 kgm.


6.14 Hammer for Collecting Electrode Rapping System.
Sketch No.VTC-011-04

At its suspension point, the Tumbling hammer is fitted with a sleeve, which is made of a
wear-resistant material, same as the bolt. The hammer is fastened to the hammer shaft by
means of a bolted clamp connection.

Experience has shown that it is more economical to replace the entire hammers when the
point of critical wear has been reached than to replace only wearing parts inside the
precipitator. It is recommended to carry out any overhaul of the dismounted hammers by
mounting a complete new suspension in the workshop. Moreover, there is a possibility of
obtaining complete hammers from VT Corp.

For replacing the hardened sleeve and the hardened bolt, which is fastened by welded-on
locking plates, the welds at the faces of the hammer handles and the tack weld laterally at
the handle have to be ground off.

The new hammer suspension comprises all the parts except for the hammer which consists
of the hammer head and the riveted-on handles.

The hardened bolt is then introduced through the new sleeve into the hammer handles and
the locking plates are re-welded to the hammer handle for keeping the bolt in place. The
locking plates must point upward to the end of the hammer handle.

When fitting overhauled or new hammers onto the hammer shaft, care must be taken that
the sleeve is clamped into the two clamp halves with its slot pointing upward towards the
hammer shaft that the fastening points are clean and the fastening bolt is tightened by
means of the stipulated torque. Then the connection is secured by a tack weld between nut
and bolt.



6. MAINTENANCE I
6.5 WEARING PARTS
VTC-011-04
Wearlna p~t - t s ~f the tumblina haymer. - Hammer f or Collectina Flectrode
Ra~pincr Sy4ht-n. VTC-011-04
V = Wear of boll V B = Wear of sleeve
To measure wear If Is recommended to dlsmental
one hammer (assuming that the wear is identical on al! hammers)

ELECTROSTATIC PRECIPITATOR MANUAL 33
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GAS CLEANING PLANT




Critical Wear:

The sleeves and bolts must be replaced if the total wear (wear inroad in sleeve plus wear
inroad in bolt) has reached 2 2.5 mm. To measure the wear, remove one hammer
(provided that wear is equal in all hammers).

Upon inspection of the system and hammer standstill care must be taken that no tumbling -
hammer is moved from its actual position particularly do not trip any hammer that is just
about to fall down as this might cause deformation by jamming the hammers against the
rapping bars upon re-starting of the rapping mechanism.

6.15 Geared Motors for Rapping Mechanisms Sketch No.VTC-011-02

For the drive of rapping mechanisms geared motors of foot mounted or flange mounted
design will be used.

For discharge electrode rapping mechanisms, the geared motor drives the cam shaft of the
release mechanisms directly via a flexible coupling unless several release devices are jointly
driven via intermediate connecting shaft and flexible couplings.

The geared motor for the collecting electrode rapping mechanism drives the hammer shaft
directly via a permanently connected drive shaft which passes through the casing wall.

The geared motor for the collecting electrode rapping drive is fitted with a hold back
device (for description and operating instructions see 6.5.10) to prevent a start in the wrong
direction of rotation which could lead to substantial damage within the precipitator if the
tumbling rapping mechanism is connected, as well as to prevent the hammer shaft from
running back during operation with the use of rapping cycle extension (stop and run
cycles).

The geared motor for the discharge electrode rapping drive has no hold back device. When
working at the cabling, for instance, it must always be observed that the motor must never
run in the wrong direction.

All geared motors are fitted with thermal winding protection. The use of a motor
protection switch with an over-current relay which can be adjusted to the rated current is
required in addition.

These grades may become necessary already in the temperature range around the freezing
point if the break-away moment of a drive has been reduced in favor of a smooth start-up
or if the motor has a relatively low capacity. Oils of ISO viscosity class are to be used for
ambient temperatures which are constantly above + 30
o
C.





ELECTROSTATIC PRECIPITATOR MANUAL 34
V T CORP PVT LTD.
GAS CLEANING PLANT




For the lubricant selected as initial filling, see the specification plate at the gear unit.

The lubricant shall protect against corrosion, shall not foam and not attack the internal
varnish, the anti-friction bearings and gear wheels as well as the gaskets. Lubricants of
various grades and viscosity classes must never be mixed, as the lubricating properties
may be impaired otherwise.

CHANGE OF LUBRICANTS:

The oil should be changed as follows:

First remove the old oil through the drain plug which is located at the lowest point of the
gearbox. Then close the drain plug again and fill in a light non-corrosive flushing oil (not
kerosene or trichloroethylene) through the filling hole located above the drain plug. The
quantity of flushing oil should be approximately equal to the quantity of the lubricating oil.

Drain off the flushing oil again after several minutes of idle run. Under no circumstances
may substantial remnants of the oil or of the flushing oil remain in the gear unit. Remnants
of the old lubricant are picked up and drained off by repeated flushing when the gear unit
is run empty

With the motor at standstill, fill in the new gear oil in the specified quantity, in special
instances up to the oil level mark.

During operation the oil level must be periodically checked and if necessary kept at the
desired value by refilling.

The anti-friction bearings of the motor are filled with anti-friction bearing grease. For
relubrication dismount motor, then clean the bearing thoroughly for example with gasoline
used for cleaning purposes or clean kerosene, then inspect and dry the bearings and
lubricate them with an aging-resistant anti-corrosion lithium-type anti-friction bearing
grease of consistency No. 2 or No. 3, whereby to max. 2/3 of the air space between the
roller bodies should be filled with grease.

Larger quantities of lubricant may cause overheating of the bearing and should be avoided.
During relubrication check whether any seals of these antifriction bearings need to be
replaced.

The oil change offers a good opportunity of sound out gear unit for unusual noises and to
overhaul if necessary.







ELECTROSTATIC PRECIPITATOR MANUAL 35
V T CORP PVT LTD.
GAS CLEANING PLANT





DISTURBANCES:

Damage arising during the guarantee period must be repaired by the manufacturers in any
case, and unauthorized repairs within this period will release the manufacturer from his
liability to consider warranty claims.

As a general rule, repairs of bearing and gear damage should be left to the manufacturers.
In case of repeated breakdown of the temperature dependent, thermal releases which are
built into the windings or of the motor protection circuit breaker find out and eliminate the
causes (check whether the rapping mechanism is locked).

Resetting the motor protection circuit breaker for a higher release current will endanger the
winding.






























ELECTROSTATIC PRECIPITATOR MANUAL 36
V T CORP PVT LTD.
GAS CLEANING PLANT



For geared motor failures not covered by the warranty some hints for self help are given on
the following pages.

Mechanical trouble and hints for its elimination

CAUSE
IDENTIFICATION
Excess
grease in
bearing or
gear unit
Insufficient
grease in
bearing or
gear unit
Foreign
matter in
bearing or
gear unit
Bearing
misaligned:
Rotor, fan
not moving
freely
Excessive
play in
gears
Gears becoming
noisy after
running a short
time without load

Check the
lubrication
chart
Increase
motor
load
Intermittent gear
noise
Clean
thoroughly

Gearbox
overheated
Check the
lubrication
chart

Gears noisy under
load
Bearing or gear damage: Return geared motor to supplier for
repair.
Grease oozing
from the bearings
or gear unit
Check the
lubrication
chart,
renew the
seal

Rotor bearings
overheat
Check the
lubrication
chart
Check the
lubrication
chart
Check the
parts,
tighten the
bolts
evenly

Rotor bearing
knocks
Clean
thoroughly

Whistling sound
on motor section
Check the
parts,
tighten the
bolts
evenly




ELECTROSTATIC PRECIPITATOR MANUAL 37
V T CORP PVT LTD.
GAS CLEANING PLANT


6.16 Hold back Device for Geared Motor.

The hold back device with self-lifting locking elements locks the geared motor in a
specified direction of rotation (indication of direction looking at the Geared Motor Output
Shaft.

Design

The hold back device is mounted to the fan cover of the geared motor. The extended gear
shaft carries the belt shaped outer ring into which a set of clamping units is fitted. This set
of clamping units consists of a cage containing individually directed spring-loaded clamps.
The clamping units rest on the inner ring which is fixed to the casing. The casing protects
the units against accidental contacts and against the penetration for foreign bodies.

Method of operation

As the geared motor is started the clamping units are raised from the inner ring and remain
free until the speed of the motor is reduced to 300 to 200 rpm after switching off or current
failure. Then the clamping units will slowly touch down onto the inner ring and at the
moment of rest may block any return motion. In the locked position power is transmitted
from the gear shaft via the outer ring onto the clamping units and from there via the inner
ring and the casing to the fan cover and the casing of the geared motor.

Power connection

For the initial start, star circuit is recommended above all for large size motors in order to
protect back hold back device from shock loads. If during a short trial run the motor is
found to be connected not in the direction of running but in the direction of locking, 2 main
supply lines should be changed as this is done for each normal reversal of the direction of
rotation.

After changing of main supply lines, check fuses and motor protection circuit breaker and
establish correct power connection as per rating plate data.











ELECTROSTATIC PRECIPITATOR MANUAL 38
V T CORP PVT LTD.
GAS CLEANING PLANT



Removal of hold back device

Release hex. Screws on casing take off casing with inner ring remove retaining ring at
rotor shaft.

Remove outer ring from the rotor shaft by means of a withdrawal device or a withdraw
hook. It is easy to remove the supporting plate for the sealing ring from the outer ring.


Altering the direction of locking

Release hex. Screws on casing remove casing together with inner ring.

Release retaining ring in outer ring.

Remove clamping units with cage turn it by 180
o
, put it back in its place, mount retaining
ring, bolt casing with inner ring onto fan cover.

Assembly

As described under Removal of the hold back device, only in reversed order. The outer
ring must be slightly heated, then place the supporting plate for the sealing ring onto the
hub of the outer ring onto the rotor shaft via the fitting key.

Maintenance

All friction parts are shop-lubricated when fitted. A re-lubrication is not necessary. Only
the sealing ring which is mounted into the supporting plate and which protects the hold
back device against the penetration of dust and moisture must be impregnated with
spindle oil on the occasion of gear oil changes in order to prevent it from drying out which
would affect its sealing properties. Remove the casing for this purpose.

9.17 Access Door

The access doors are provided with seals in order to prevent the temperature from falling
below dew point level due to air-in-leakages and thus to prevent corrosion. The seals must
always be in perfect condition.

The seal is placed in a groove running all around the inside of the door. A special frame
seal is used.




ELECTROSTATIC PRECIPITATOR MANUAL 39
V T CORP PVT LTD.
GAS CLEANING PLANT



Critical Wear:

The seals must be replaced when their proper function is no longer ensured e.g. due to
hardening, excessive deformation or damage. Normally the frame seal is glued in.

The protection doors mounted in front of the access doors are also fitted with a seal which
normally needs not to be replaced; if necessary (in case of damage) it may be replaced as
well.

The frames of the access doors on the side wall of the precipitator giving access to the
Internal Walkways are firmly welded to the casing and are provided with an earthing
bar for the connection of an earthing rope of an earthing rod. When entering the
precipitator or more precisely when actually opening the door all safety measures as
described under

6.1 must be strictly observed. The door can be opened and closed only with the aid of a
wrench (hex, nut M16, key size 24) Uniform tightening of the nuts must be assured.


Critical Wear:

The seals must be replaced when their proper function is no longer ensured, e.g. due to
hardening, excessive deformation or damage. Normally the frame seal is glued in.

An insulating pad, which is to extend around the edges of the door, is provide before each
door for the thermal insulation. The outside cover consists of insulating plate sheeting. It
must be observed that the insulating pad will be carefully treated and that it is properly re-
inserted after closing the door.

The access door frames attached to the casing are provided with an earthing bar for the
connection of an earthing rope of an earthing rod. When entering the precipitator or more
precisely when actually opening the door all safety measures as described under 6.1 must
be strictly observed. The door can be opened and closed only with the aid of a wrench (hex.
nut M16, key size 24) Uniform tightening of the nuts must be assured.












ELECTROSTATIC PRECIPITATOR MANUAL 40
V T CORP PVT LTD.
GAS CLEANING PLANT



III. SPECIFICATIONS

1. General requirements

a) For connection and disconnection of electrostatic precipitators and for the opening
and entering into precipitators it must be ensured that no hazards can be created by
process media, e.g. gases, dusts, etc.

b) Lockable openings through which voltage-carrying pats can be touched or reached by
entering the precipitator must be kept closed. Preventive measures at other openings
which, due to the nature of operation, cannot be secured against unauthorized opening,
e.g. inspection windows, must not be rendered ineffective.

2. Operation of Power Installations

When working in or at electrostatic precipitators, portable electric torches, electric tools and
electric arc welding rigs may be used only if they conform with pertinent IS standards.

3. Maintaining Proper Working Condition

Depending on the nature of the operation, electrostatic precipitators must be cleaned at
appropriate time intervals. They must be checked for operational condition prior to new
start-ups.

Associated parts of electrostatic precipitator plants must be so identified that the
association is readily recognizable and confusions will be avoided. Openings through
which voltage- carrying parts can be reached must be marked. In multiple-zone
precipitators, the accessible zones must be clearly recognizable from their markings at the
access openings.

4. Producing and securing off-circuit conditions prior to commencement of and clearance
for work.

a) Isolation
Electrostatic precipitators must be isolated before opening or removing the protective
devices against accidental contact (opening of manhole covers, etc.) if the voltage-carrying
parts are within reach of hand and there is no protection against accidental contact. The
disconnection of the electrostatic precipitator by door contact does not mean that the
insulation is unnecessary.











ELECTROSTATIC PRECIPITATOR MANUAL 41
V T CORP PVT LTD.
GAS CLEANING PLANT





b) Securing against reconnection

If the switches serving for isolation of the electrostatic precipitator plant are not arranged in
closed switchgear rooms, additional safety measures must be taken against unauthorized
connection, e.g. by locking the switches. Warning plates alone will not suffice in this case.


c) Earthing and short-circuiting

Before the electrostatic precipitator is entered, the discharge system must be earthed.
Movable elements, e.g. doors and covers must not be used for connection of earth
conductors. The earth conductors must be connected at the points provided for this
purpose.

During any work performed in and at the precipitator, additional and visible earth
connections must be employed at the place of work. A connection between collecting
electrodes and discharge system will suffice for this purpose.

Other metal materials than copper may be used for earth conductors. The cross section
must measure at least 10 mm
2
. Chains, owing to their unreliable contact-making properties,
must not be used as earthing device.

During work carried out on cables, earthing and short circuiting must be performed also at
the point of disconnection and transition from cable to electrostatic precipitator.

5. Working near voltage carrying parts

Before starting work in the area of an electrostatic field in a multiple-field precipitator, the
measures specified in section 4 must be taken for all fields unless the necessary protection
against unintensional contact is ensured by the precipitators structural design.

All openings are to be marked by warning plate with additional information plate possibly
with the plate Attention: Multiple Power Feed-In in addition.









IT- PRECIPITATOR IN'I'ERNAL. ASSLY. 1 VTC-780-001 I
I I 'OR' I PRECIPITATOR INTERNAL ASSLY. I VTC-790-001
1






INSTALLATION OPERATION
&
MAINTENANCE MANUAL






RF LEVEL SWITCH
MODEL : 550












EIP ENVIRO LEVEL CONTROLS PVT LTD
NOIDA - INDIA
2

CONTENTS


I. INTRODUCTION 1
A. Application
B. Control Configuration
C. Equipment Specification

II. INSTALLATION 4
A. Receiving & Inspection
B. Electronic Transmitter
C. Sensing Probe
D. Electronic Protector
E. Wiring
III. OPERATION 7
A. Start-Up
B. Calibration
IV. MAINTENANCE 8
A. Normal
B. Trouble Shooting
C. Manufacturer Assistance
V. DRAWINGS
VI. APPENDIX
A. Installation Check Points
B. Complaint Format
C. Installation Tips
D. Application Data Sheet for future / additional requirements
or new applications

3

LEVEL SWITCH
FOR GRANULAR MATERIALS & LIQUIDS

1. INTRODUCTION

A. APPLICATION

The instruction in this manual pertain to the Model -550 Level Control based on
Radio Frequency principle capable of monitoring the level of material present in a
vessel at a preset point. The relay contacts may then be used to operate other
devices.
The Model - 550 point level control utilises an electronics to provide Precision
Reliability Independent of Moisture material temperature, Coating Transit
material Suspended dust etc., meaning thereby it can be used with wide variety
of materials which may be conductives, non conductive solids, liquids, corrosive
or even tend to coat on the sensing probe can be accurately measured and
controlled.

A. CONFIGURATION

RF Level Switch comprises of an Electronic Controller, a Sensing Probe &
Co-axial Cable for the connection of the Electronic Controller to the probe.
Controller provides RF signals to the probe and measures the changes in
parameters provided by the sensing probe mounted in the material (to be
measured) container. The Sensing Probe do not contain any electronics.

RF signal provided to the probe varies with the change of media (the application
material having interparticle cohesive contact) upto the vessel body as reference
ground. The material in transit or the suspended particles which do not have
cohesive intraparticle contact upto the vessel shell are ignored. The vessel part
selected for the probe mounting does not act as reference ground, as long as
shield section is placed physically between active section of the probe and vessel
body part where the probe is mounted. The variation in RF signal is utilised to
activate a relay and its contacts are available as output for further use. To protect
the equipment from electrostatic charge developed in the vessel/hopper an
Electrostatic Charge Protector is provided in the Probe Head.

Drawings of electronic unit, sensing probe and electrostatic protector with
connection details are included in this manual in Section V.
4
B. EQUIPMENT SPECIFICATION

1. ELECTRONIC CONTROLLER MODEL - 550

Line Voltage
Line Voltage Sensitivity

220 /110/24 VAC OR DC OR as specified
10%
Frequency Hz 50 / 60 10% for AC Supply
Power Consumption 3 VA Approx.
Ambient Temperature Limits (-) 10 to (+)60
o
C. or as specified
Output Relay 2 sets of Change over potential free contacts
(SPDT) or as specified.
Contact Rating 5 AMPS 220 VAC non-inductive or as specified
Local LED Indications
Green
Red
Yellow

Normal Level
Alarm Level
Probe Healthy : LED glows off in the case of
Probe or probe cable short circuited to ground
or supply off. It is not effected by loose open
probe cable connection i.e. yellow LED
continues to glow viz.
Probe / Cable proper connection must be
ensured.
Cable length, Electronic unit
to probe, Special cable
supplied by EIP only.
25 Mtrs (max.) unless confirmed by EIP.

2. SENSING PROBE

Model
PR-550 RT ST /
ESP / BE/ FLX
PR-550 HT
PR-550
FLSH
Ambient Temp. 250
o
C (Max.) 600
o
C 260
o
C
Vessel Pressure Customer Specification ___________________________
Probe Type _______Rigid or Flexible ___________________Flush / DISC
Material Construction
Exposed Metal SS 304 SS 316 SS-304
Insulation PTFE Ceramic PTFE
Insertion Length
mm
50 to 10000 50 to 7000 Zero
Mounting 40 / 20NB BSP threaded or flanged Flanged

Note : For other special requirements contact EIP ENVIRO.
5

3. PROBE HEAD
For use with SWITCH Model Probes
Construction Cast Aluminum
Connection Sizes Probe 1 BSP
Conduit / Cable Gland connection : BSP
Size : Ref drawing in section V

4. ELECTROSTATIC PROTECTOR

Mounting Provided inside the Probe Head
5. CABLE-Model SWITCH -226
For connection of Probe and Electronic Controller


CABLE Special coaxial cable, connection
Centerwire for Probe connection,
Middle shield for Signal
connection, Top layer wire for
Ground Connection
Conductor Copper
Insulation PVC/PTFE

6

II. INSTALLATION

A. RECEIVING & INSPECTION

To ensure proper receipt of material, it is important to immediately check
the content of shipping containers. Contents should be compared against
packing list to ensure proper equipments have received and that it has not
been damaged during transit. If any discrepancies arise, consult EIP factory.

B. ELECTRONIC CONTROLLER

1. UNIT LOCATION

The following should be considered while mounting the electronic controller :

Location Mount on convenient structure (near to
probe location) free from obstruction, at
man height for easy operation.
Temperature Be sure ambient temperature at
installation point does not exceed unit
temperature limitation, (-) 10 to (+)
60
o
C.
Environment Install unit at a location so that no
exposure to direct sunlight, rain or
snow
Vibration If excess vibration in the area is
anticipated, consider alternate
mounting area or place vibration
absorbing material under enclosure
base.
Distance Be certain cable distance from probe to
electronic controller is minimum
possible and does not exceed 25 mtrs.
maximum.
(For longer cable length confirm with
EIP)

2. CABLE CONNECTION

Make cable connection as per drawing enclosed (as part of this manual) in
section V. etc. and ensure that there is no chance of damage /
disconnection/shorting of cable/cable connection in future.
7


C. PROBE (IMPORTED)

1. LOCATION & INSTALLATION

The following should be considered while mounting sensing probes.
i. Verify that material will cover the active section of the probe at the proposed
mounting location consider the probe length.
ii. Be certain that shield section of the probe must project freely inside the
vessel (at least 1 or 25 mm) for Rod type/flexible probes.
iii. Be certain there is a sufficient clearance outside the hopper for inserting and
wiring. For thermal insulated vessel use lagging extension (of length equal
to thickness of insulation) for easy access to terminals.
iv. Disc type (flush mounted) probe must be either flushed with inner surface of
hopper wall or may project inside (up to 5mm) but not remain behind the
inner surface of the vessel.
v. Probe must be almost perpendicular (90 + 15
o
) to the vessel wall on which
probe is mounted, unless confirmed by EIP.
vi. Active section must not be too close to any other grounded metal part/of the
hopper/Vessel maximum possible gap must be maintained. Preferable
location along centre line of the wall/plate of the vessel.
vii. Termination must be done with proper lugs & gland and each conductor
must be totally isolated from each other.
viii. Flexible/Probe length is selected considering angle of response (for solids),
roof thickness, mounting nozzle height etc. As rule of thumb for solid
materials, horizontal distance from fill point/points must be less than the
insertion length of the probe.
ix. Select location for flexible top mounted sensing probe nearest (possible) to
the vertical center axis of the filling point/points & maximum possible
distance from side walls.
x. Probe grounding of Hopper/Vessel body with electronic controller must be
ensured
xi. Do not provide additional metallic protection like pipe/channel/plate inside
the vessel covering the sensing probe, if provided must be removed, as this
can result malfunctioning. For large size particles (side mounting), use disc
type flush mounted model SWITCH-FP probes.
xii. Coaxial cable supplied/specified by EIP only to be used for the connection
of sensing probe to electronic unit.
For and additional queries contact EIP application engineering staff, if required.
8

D. ELECTROSTATIC CHARGE PROTECTOR

Electro-static charge protector is provided on all applications where the possibility
of electrostatic charge build up on the probe exist. This protector, a small board
is mounted inside the Probe Head. It fastens directly to the active section of the
probe via screw connections. The probe cables from the electronic unit are
fastened to Terminal connections on this board.

E. WIRING

1. PROBE CABLES
CABLE EIP provides coaxial cable for
connection of electronic unit to probe.
Termination Hook-up of the probe cable requires
connections of the three cable
conductors centre wire (CW) to PR,
Middle layer (MW) to SH and Top
Layer Drain wire (DW) to G at both
electronic controller and probe. Refer
the Drawing in Section V.


2. POWER CONNECTIONS

Power connections (as specified) as made directly to the terminal blocks located
in electronic controller. Due to the low power consumption of the unit, (3VA) light
gauge wiring of size 1.0mm sq. may be sufficient. However, consult the local
Electrical Regulations for exact wire guage selection.

3. OUTPUT CONNECTION

Output relay connections are made directly to the terminal blocks located inside
the electronic controller. These relay contacts (two numbers change over
potential free contacts) are rated for 5Amp at 220 VAC non-inductive or as
specified. Output wiring should be compatible with the intend output load (less
than relay contact rating)





9


III. OPERATION

A. START-UP

Before start-up ensure that all the following must comply.

1. ELECTRONIC UNIT
1. Ambient condition suitable (-10 to+60 Deg. C. Max.).
2. Electronic unit installed at convenient man height.
3. Electronic Unit not exposed to direct sunlight, rain or snow.
4. Fasteners tightened properly.
5. Earthing grid connected at both the earthing terminals of electronic unit.
6. Supply voltage is as specified on the terminals.
7. Cable used from electronic unit to probe is EIP supplied/EIP specified Cable
length from Electronic Unit to probe is less than 25 Mtrs. Centre wire
connected to PR, middle layer to SH & top layer/drain wire to G at both
ends.
8. Glands used for cables are proper.
9. Proper Lugs are provided at both ends of the cable.
10. Proper Dressing of cable done with cable tray/conduct for all the cables to
ensure no disconnection / damage in future.

2. PROBE
1. Probe Mounted 90 (+/-) 15 Deg to vessel wall / plate
2. No Pipe cover/Hood/Canopy inside vessel over/near probe.
3. Maximum gap from other walls / any other metal parts.
4. Shield section projection inside the vessel more than 25mm (1)
5. If flexible probe mounted from top only and distance from fill point less than
length of the probe.
6. If flushed probe : either flush with inner surface of the vessel or projects
inside upto 5mm (all around the probe).
7. Verify probe ground terminal shows firm continuity with vessel / vessel
structure earthing grid.
Switch on the appreciated supply voltage and yellow & either green or red local
indications glow.
10

B. CALIBRATION

The instrument has been factory calibrated for use in the majority of
applications, However, due to variations in installations, it is advisable to
field verify this setting. This may be accomplished using the following
procedure. For maximum accuracy, all calibration adjustments should be
made with the vessel/hopper at operating conditions.

1. Ensure the level of application material well below the probe.

2. If time delay opted, select Cal/Opn switch to Cal

Check local indications LED (Green or Red) Green LED should glow, if not
turn adjustment clockwise (CW) so that green LED glow and Red LED
glows off.
Turn the turning adjustments counter-clockwise (ccw) counting the number
of revolutions until the local indication LED just glows Red.
Turn the adjustment clockwise (cw) slowly until the local indication LED just
glows Green.

3. Turn further cw turns to preload the setting.
4. Increase the material level above the desired level of operation and check
the unit operation, the local indication LED glows RED/
5. If unit does not respond, the preload setting must be reduced.
6. Verify once again with material level for satisfaction of calibration.
7. If time delay opted select Cal/Opn: switch to Opn.

CALIBRATION IS NOW COMPLETE

IV. MAINTENANCE

A NORMAL

The EIP SWITCH models are designed for years of maintenance-free service.
This is ensured by use of no moving parts in the unit except the output relay and
there is no electronics or any sensitive part in the sensing probe.
11

B. TROUBLE SHOOTING

1. ELECTRONIC CONTROLLER

Verify supply voltage at supply terminals, if it is as it should be Yellow LED and
one of Red or Green LED glows, if not, check Fuse (rating 100 mA)
a. Disconnect the probe cable connections (centre wire, shield wire, ground
wire,) at the electronic unit. Leave (specified) power connected.
b. Hold two Screw Drivers in your hands from non conductive portion.
c. Touch the Screwdriver G and PR terminals (Probe Connection) at the
Electronic Controller.
d. Touch the metallic portion of the screw drivers by fingers. Proceed to B1e
(below).
e. If the relay actuates and de-actuates on disconnecting the screw driver from
the terminal PR and again actuates by replacing the screw drivers at terminal
PR, the Electronic Controller is working properly. Proceed to section IV B-2
checking the Probe.
f. With probe cable connection disconnected at electronic unit, a Volt-ohm
meter (VOM) which is set on low DC Voltage range (20 VDC) Proceed to g.
g. With specified input power applied to the electronic unit, measure the
following voltage on the unit terminals.
i) Probe to ground .. VDC
ii) Shield to ground ..VDC

The above values should read with in 2 to 5 VDC Value (I) should read 5 to
10% less than value (ii)
a. If you were unable to get required results e and g above then there is fault
in the electronic unit. It is recommended that the electronic controller be
returned to EIP for repair see Section VC.

2. PROBE

a. Reconnect coaxial cable (Probe Cable) to electronic unit.
b. Repeat IV B1 f & g corresponding with material level below probe.
i) Probe to ground .. VDC
ii) Shield to ground .. VDC
Both should read with in 20% of the values obtained in IV 1g
c. If possible, repeat IV B1 f&g corresponding with material level above Probe.
12
i) Probe to ground .. VDC
ii) Shield to ground .. VDC
Both should read within 10% of the values attained in b.
d. If measurements obtained in 2b & 2c are as they should be ie within 10% of
the values obtained in 1 B1g verify calibration as per Section III C.
e. If measurement are not as they should be, proceed to f & B3.
f. Disconnect cable at probe also remove the electrostatic protector (with probe
still in its position, mounted on the hopper). With the VOM in the resistance
scale, measure the following probe values.
Probe uncovered with material
Probe to shield .. OHMS
Shield to ground..OHMS
Probe to ground .OHMS
All above values should read above 1M Ohms, if not, remove the probe from its
position and repeat 4B2f if values are above 1 Mohms check installation as per
3b2, if not, proceed to IV C.

3. PROBE CABLE

a. Disconnect Probe cable at both probe and electronic unit.
b. Using VOM on the resistance scale measure the resistance between centre
wire (CW) and middle layer (MW) of the cable end at the electronic unit. This
reading should be infinite open circuit.
c. If infinite in b, short CW and MW at probe end of the cable using a short
jumper measure resistance between CW and MW at electronic unit end of
cable. This reading should be zero, (Short-Circuit)
d. Repeat step b and c measuring between MW and ground wire (DW) Reading
should be as above.
e. If reading are correct, confirming continuity and no shorting of the cable the
probe cable is in proper condition.
f. If reading are incorrect, check cable for loose or broken terminations or
shorting. If none can be found, the cable should be replaced.
13

4. OUTPUT CIRCUITRY

The output circuit of the instrument consist of two sets change over contacts
brought out to terminal blocks. These contacts open and close in response to
material level change. Relay operation may generally be heard as an audible
click Relay operation can also be checked placing VOM, set on resistance
scale between terminal block points on NC and COM. The VOM reading should
change from OHMS to infinity when material contacts the probe or when the
probe terminal PR is touched with finger, and change of local indication LED
from Green to Red.

C. ASSISTANCE

If problems exist other than those mentioned above or if the attempts to locate
the problems fail, call the EIP factory and ask for the service department at the
following address with details of the problem faced in the complaint format issued
included in this manual Appendix B by EIP further guidance/deputation of
representative for attending the problems.


EIP ENVIRO LEVEL CONTROLS PVT LTD
B-130, SECTOR-X,
NOIDA 201 301 (U.P.) INDIA.
TEL. : 0120-2442527 & 2442528
FAX . : 0120-2555767
Email : eipindia@vsnl.net.in