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INSTRUCTION MANUAL

Electrostatic precipitator
Maintenance

52201-04

Type E

The information transmitted by this document is the proprietary and confidential property of FLSmidth, and may not be dublicated, disclosed, or utilized
without written consent from FLSmidth.

.....9 3..........................................2 Cleaning ...............................4 2.......................52201-04 2 Enclosures: Service report (2 pages) Sketch of precipitator (top rapping) Sketch of precipitator (bottom rapping) Sketches Sketches Sketches Sketches Sketches Sketches Sketches Sketches Sketches 52201-04-I 52201-04-II 52201-04-IIa 52201-04-III 52201-04-IV 52201-04-V 52201-04-VI 52201-04-VII 52201-04-VIII 52201-04-IX 52201-04-X 52201-04-XI Text reference is made to the following instruction: Geared motor Operating manual High-tension rectifier Table of contents: Page: 1.....7 2.............................................................4 Checking of condition ...5 2.5 2........................................................... and may not be dublicated.........................5 2........6 Performance test ............ or utilized without written consent from FLSmidth....................................................................................................... disclosed.......................................................... General....................................................................................5 Replacement........................................................................................ Maintenance..................................................................... ............ Key to sketches ...1 Lubrication...........................................................9 2..............................................................................3 2..........................3 Inspection and adjustment ...........................................10 Performed by / Date MEP/ 030507 Checked by / Date LG/ 030507 Approved by / Date MEP / 030507 The information transmitted by this document is the proprietary and confidential property of FLSmidth................................................

outlet. . NOTE! No work on the electrostatic precipitator must be commenced before the person in charge has made himself conversant with the safety regulations described in the instruction for electrostatic precipitator operation. Enclosure I shows an example of a check list which is used by FLS specialists in connection with the inspection of electrostatic precipitators. General We recommend the presence of an experienced FLS Airtech precipitator specialist at the annual inspection with a view to determine and plan the maintenance work for subsequent year's inspection. The casing mentioned can be made of steel or concrete.52201-04 3 1. For this precipitator see the Dimension drawing and the Main parts list. These regulations must be strictly adhered to. and may not be dublicated. or utilized without written consent from FLSmidth. disclosed. This instruction is mainly about maintenance of the internal parts. bottom hoppers and gas distribution screens can have many designs. The information transmitted by this document is the proprietary and confidential property of FLSmidth. Inlet.

5 . A A . . A . .4 . . disclosed.: 01 02 03 04 05 06 07 08 09 10 11 12 13 14 15 16 17 18 19 Text: Precipitator compartment/ outlet ducts Insulation Inspection doors Insulator compartment Drive station for rapping gears Collecting plates Collecting rapping gear Discharge electrodes Discharge rapping gear Split bearings Guard plates Supporting insulators Insulator shafts Gas distribution screens . . . . 4 Maintenance Preventive maintenance.5 . T . . survey . . . . A(T) A . . . . . A(T) . . or utilized without written consent from FLSmidth.52201-04 2. . . . . . A 2A A . 2A 2A . . . 2A . . .3 . . . . .3 . . . . Rectifiers Geared motors Heating elements Thermostats Lead-in insulators A = yearly T = see text in instructions . T . .1 . . . For instance: 2A = twice a year. .2 . A number in front of the letter indicates how often the procedure is to be carried out. . 2A 4A . .2 . and may not be dublicated.6 . 4A . . A . A . . . . .) Performance test Pos. . . . The information transmitted by this document is the proprietary and confidential property of FLSmidth. . .4 . . 2A . . . . T T . A A A . . A A . .1 . A . T . . A . 2A A A .6 Lubrication Cleaning Inspection and adjustment Checking and condition Replacement (lubricants incl. . . A .

1 Lubrication Drive stations for rapping gear (05) See enclosure III Lubricate the bearing to the right. Check the heating element performance. brush or high-pressure steam.3 Inspection and adjustment Insulator compartments (04) See enclosure IV Check that lid packings (A) are intact. Check that the connection is tight. Collecting plates (06) Remove abnormally large dust coverings. If air flushing is provided. .2 Cleaning Precipitator compartment (01) Remove all coverings and dust deposits with scraper. If air flushing is provided: Check that the air flushing functions correctly. 2. disclosed.52201-04 5 2. Remove cover (21) and clean the insulators on the inside of dust and impurities. possibly with a bottle cleaner. Gas distribution screens (14) Remove all dust from screens and guide plates. Supporting insulators (12) Clean the insulator surfaces of dust and impurities. insulating part of the shafts. with heat resisting grease such as MOLYKOTE G-n plus or NEVER SEEZ Geared motors (16) See separate instruction. Lead-in insulator (19) (not shown) Clean the insulator surface of dust. Check that the compartments have been cleaned. clean the box in side which the shafts are mounted. soft and closing tight. and may not be dublicated. 2. or utilized without written consent from FLSmidth. Check the thermostat setting. Insulator compartments (04) Remove all dust deposits and clean the insulator compartments. The information transmitted by this document is the proprietary and confidential property of FLSmidth. Insulator shafts (13) Clean the corrugated.

Check that the electrodes are not damaged at the guiding end.52201-04 6 Drive stations for rapping gears (05) See enclosure III Check that the sealing bellows adjusting dimensions do not exceed 125 mm (dimension a). Check the drop hammer pivot bolts and their holes for wear. Split bearings (10) See enclosure VI Check that the bearing wear at the bottom of the bearing is not higher that the shaft has sunk max. Vertical adjustment is made by raising or lowering shaft holder A. and may not be dublicated. See instruction for operation. Check the rapping gear timer. Replace the electrode if the bush has been burnt off. Then replace the bearing by a special bearing with bush (Z). adjust on bolts (D). Check that the drive station shaft centres relative to the inside driven shaft. Collecting rapping gear (07) Top rapping: See enclosure V and bottom rapping: See enclosure XI. . the bearing bush must be replaced. Horizontal adjustment of the impact point is made by moving the hammer by means of the fixing clamps. If dimension a exceeds 125 mm. If the bush has seized on the guide pin it can be loosened by carefully pulling/pushing the electrode. Check the fixture of the drop hammers on the rapping gear shaft. or utilized without written consent from FLSmidth. Note: Dimension b must be min. Check bearing bush (B) for wear. (Y). disclosed. section c-c Check that the electrodes are not bent so that tension distances a ± 5 mm is no longer adhered to. The bearing function is not affected by the increased clearance. Discharge electrodes (08) See enclosure V. the bearing may be turned through 180° and be used in this position until the wear is 8 mm again. If so. Loosen the stop blocks and fix them in the new position by welding. (X). If there is more wear. Dimension c must not exceed 8 mm. 2 mm. If required. flange (A) must be loosened and the bellows be compressed to a = 117 mm. The information transmitted by this document is the proprietary and confidential property of FLSmidth. Check that the impact point is positioned within the tolerances (Horizontally ± 5 mm and vertically ± 5 mm). Straighten bent electrodes carefully by pushing or pulling them. 8 mm.

Check that the impact point is located within the tolerances (sideways ± 8 mm and vertically ± 5 mm). Loosen the stop blocks and re-weld them in the new position. Check the collecting plates for corrosion. Collecting plates (06) If the plate has become skew. and may not be dublicated. Check that the plates do not have any abnormally large dust deposits. Skewness to be corrected carefully with the supplied straightener or spot heat so that the discharge electrodes are not exposed to heat. Check that the a-dimension between discharge frame tubes and collecting plate edges is ± 5 mm everywhere. it must be straightened. Drive stations for rapping gears (05) See enclosure III Check bearing bush (B) for wear. In case of large deposits. Check that insulating plate (B) is intact and is a tight fit against the frame c. Inspection doors (03) See enclosure VIII Check that packings (A) are intact and soft and that the door closes tight everywhere. Check the insulation of the parts concerned and replace/repair if required. or utilized without written consent from FLSmidth. check the functions of rapping gear and timer. Discharge rapping gear (09) See enclosure VIII Check the drop hammer fixture on the rapping gear shaft. straighten it with a fork. Should the plate twist. it may be required to align the entire discharge system with the assistance of FLS Airtech's head office. replace the bush. Vertical adjustment is done by raising or lowering the split bearing bracket B or by inserting intermediate plates. repair or replace sheet parts. Insulation (02) Check that the insulation is intact everywhere and the insulation covering is waterproof. . The information transmitted by this document is the proprietary and confidential property of FLSmidth.52201-04 7 2. disclosed.4 Checking of condition Precipitator compartment (01) Check the sheet parts for corrosion. If not. If required. If clearance (c) exceeds 8 mm. The impact point is adjusted sideways by moving the hammer with the fixing clamps. which are corroded.

On precipitators with air flushing check the thermostat-controlled heating element at the insulator shaft. See instruction for operation. Heating element (17) Check that the passage resistance to earth is minimum 0.52201-04 8 Check the drop hammer pivot bolt/hole for wear. Lead-in insulator (19) Check that the insulator is free from crack and dust deposits.5.5 MΩ or in compliance with the Local Regulations. It will do to replace the bolt as a temporary repair. disclosed. insulating part of the shaft is clean and free from ruptures and cracks. Retighten all live connections. Bottom hopper heat Precipitators with electrically heated bottom hopper: Check the function of the heating elements. Gas distribution screens (14) Check that the screens are not obstructed by dust. Rectifiers (15) Check and retighten all live connections. Insulator shafts (13) See enclosure IX Check that the corrugated. See separately forwarded instruction. or where there are abnormally large dust deposits. Supporting insulators (12) Check that the insulators are not cracked. mark these areas on a sketch which is to be forwarded to FLS Airtech for detailed advice. Geared motor (16) See separately forwarded instruction. Cracked insulators must be replaced. Replacement of insulator shaft: See sub-section 2. replace the hammer. Check that the guide vanes are fastened and that the angle relative to the gas distribution screens is the original one. Check the temperature setting on the temperature monitoring relay for thermo sensor (20). Check the clearance of the coupling halves. and may not be dublicated.5. See sub-section 2. If the hammer head can be moved more than 12 mm. Check the rapping gear timer. or utilized without written consent from FLSmidth. If there are areas on the screens which are particularly worn due to dust. . The information transmitted by this document is the proprietary and confidential property of FLSmidth.

Assemble yoke E around the lifting bar and tighten nut F so that the weight of the discharge system is just supported. Remove the mounting frame. disclosed. b and c. and may not be dublicated. Split bearings (10) See under Split bearings.52201-04 9 2. sub-section 2. . Tighten nut M so that the weight of the discharge system is supported by same. The information transmitted by this document is the proprietary and confidential property of FLSmidth.8. Mount the cover. Loosen nut G and then lift nut and upper supporting flange into position H. Insulator shafts (13) See enclosure IX Replace the insulator shaft by loosening bolts in the drive station and displacing the shaft. Supporting insulators (12) See enclosure X Before beginning to replace a supporting insulator. b and c. Place mounting frame A on insulator compartment B. Lift the supporting insulator into position K by means of lifting tool J. Only use the specified bolts of quality ISO 8. Check and possibly adjust distances a. or utilized without written consent from FLSmidth. remove the old packings.6 Performance test Heating elements (17) (not shown) Test the function of the heating elements. check the sealing device as described in sub-section 2. Lift the defective supporting insulator out and lift the new one into place. When mounting a new insulator shaft or adjusting the clearance. an earth connection must be established in the lead-in box at the high-voltage connection. For mounting use the reverse procedure. Remove the cover and measure and record distances a.5 Replacement Discharge electrodes (08) Fasten new electrodes with a torque spanner which is adjusted for 47 Nm.3. Turn yoke L beneath and assemble it.4. Loosen nut F and swing aside yoke E. clean the packing faces and mount new packings. 2. Fasten lifting bar C on supporting bar D. Thermostats (18) (not shown) Test the function of the thermostats. Finally clean the insulator compartment of dust and coatings which may otherwise cause sparkovers.

10 Key to sketches 01 02 03 04 05 Filter chamber. and may not be dublicated. or utilized without written consent from FLSmidth.52201-04 3. inlet duct Insulation Inspection door Insulator compartments Drive station for rapping gears 06 07 08 09 10 Collecting plates Collecting rapping gear Discharge electrodes Discharge rapping gear Split bearings 12 13 14 15 Supporting insulators Insulator shafts Gas distribution screens Rectifiers 16 17 18 19 20 Geared motors Heating elements. . disclosed. top and bottom Thermostats Lead-in insulators Temperature sensor ---o0o--- The information transmitted by this document is the proprietary and confidential property of FLSmidth.

: FLS' ref.OUTLET 1a Precipitator roof (straightness roof beam. mobility) 2b Collecting plates (corrosion. dust layer) 2c Supporting irons (straightness) 2d Guides (wear) 2e Guard plates (attachment. corrosion-plate) 1d Inlet duct (corrosion-plate. corrosion-plate) 1c Precipitator bottom (straightness beam. wear) 1f Distribution shields (dust layer. cleanness) 1k Roller bearings (expansion possibility) 1l 1m 1n 1o 2. wear) 1g Outlet duct (corrosion-plate. corrosion) 1j Insulator compartments (corrosion. straightness) 2g Alignment of systems (special control measuring) 2h Bearings (wear) 52201-04-I The information transmitted by this document is the proprietary and confidential property of FLSmidth. or utilized without written consent from FLSmidth.INLET . clearance) 2f Rapping bars (crackings. COLLECTING SYSTEM 2a Collecting plates (straightness. dust layer) 1e Horizontal grate (dust layer.: Conclusion of precipitator inspection: Checked Adjusted In order See item 7 1 CHAMBER .Plant: Service Report Electrostatic Precipitator Type: Inspected by: for Date: Client's ref. corrosion-plate) 1b Precipitator casing (straightness columns. and may not be dublicated. dust layer) 1h Distribution shields (dust layer) 1i Inspection doors (tightness. disclosed. .

dust layer.centre (straightness. wear) 3r Slip ring in drive stations (wear. . tightness) 2o Metal bellows in drive stations (corrosion. tension. lubrication. tension) 3m Internal chain wheels (wear) 3n Gear motors (oil level) 3o Chain drives (tension. DISCHARGE SYSTEM 3a Upper supporting beams (straightness) 3b Impact beams (wear) 3c Diagonal rods (tension) 3d Frame parts. lubrication.2i Expansion couplings (expansion possibility) 2j Drop hammers (wear. disclosed. wear) 2n Slip ring in drive stations (wear. lubrication. tightness) 3t Bearing bushes in drive stations (wear. dust layer. upper . tension. impact point) 3k Supporting insulators (crackings. tightness) 2r 2s 2t 2u 3. tightness) 2p Bearing bushes in drive stations (wear. or utilized without written consent from FLSmidth. wear) 3p Ball bearings (fixing. wear) 3h Bearings (wear) 3i Expansion couplings (expansion possibility) 3j Drop hammers (wear. lubrication. wear in hooks) 3e Alignment of systems (special control measuring) 3f Discharge electrodes (tension. and may not be dublicated.lower . tightness) 3s Metal bellows in drive stations (corrosion. impact point) 2k Gear motors (oil level) 2l Chain drives (tension. wear) 2m Ball bearings (fixing. wear in hooks) 3g Insulator shafts (expansion possibility. cleanness) 3l Internal chains (wear. tightness) 3u 3v 3x 3y 52201-04-I The information transmitted by this document is the proprietary and confidential property of FLSmidth.

or utilized without written consent from FLSmidth. disclosed.52201-04-II The information transmitted by this document is the proprietary and confidential property of FLSmidth. and may not be dublicated. .

52201-04-IIa The information transmitted by this document is the proprietary and confidential property of FLSmidth. or utilized without written consent from FLSmidth. . and may not be dublicated. disclosed.

disclosed. and may not be dublicated. or utilized without written consent from FLSmidth. .52201-04-III 52201-04-IV The information transmitted by this document is the proprietary and confidential property of FLSmidth.

or utilized without written consent from FLSmidth. and may not be dublicated.52201-04-V The information transmitted by this document is the proprietary and confidential property of FLSmidth. disclosed. .

or utilized without written consent from FLSmidth.52201-04-VI 52201-04-VII The information transmitted by this document is the proprietary and confidential property of FLSmidth. . and may not be dublicated. disclosed.

.52201-04-VIII 52201-04-IX The information transmitted by this document is the proprietary and confidential property of FLSmidth. and may not be dublicated. or utilized without written consent from FLSmidth. disclosed.

or utilized without written consent from FLSmidth. disclosed. and may not be dublicated.10 11 12 52201-04-X The information transmitted by this document is the proprietary and confidential property of FLSmidth. .

52201-04-XI The information transmitted by this document is the proprietary and confidential property of FLSmidth. disclosed. . and may not be dublicated. or utilized without written consent from FLSmidth.