Doc. No.

MAINTENANCE STANDARD REPORT Issue Date xx xx xxxx

Revision No. 00
Title:
DRY CLEANING AND INSPECTION ESP UNIT #2

Major Schedule For Dry Cleaning and Inspection ESP Unit #2

No. Date Description Detail Description Remarks
1 Day 1 1. Team manpower arrived at Babelan site
AEP team arrive to site 2. Safety training
2 Day 2 Preparation 1. Tools and machine arrived and shift to ESP #2
2. Open all manhole at side and top of ESP and
open all insulator cone ceramic box cover
3. Connection for air compressor pipes
4. Connection for all lighting and fans blower
5. Install scaffolding for hopper and open
expansion Joint at hopper outlet flange
6. Alignment the cover for hopper
3 Day 3 Cleaning For First Field Cleaning inside of ESP
4 Day 4 Cleaning First and Second Cleaning inside of ESP
Field
5 Day 5 Cleaning Cleaning For Second Field Cleaning inside of ESP
6 Day 6 Cleaning For Third Field Cleaning inside of ESP
7 Day 7 Cleaning Third and Forth Field Cleaning inside of ESP
8 Day 8 Cleaning For Forth Field Cleaning inside of ESP
9 Day 9 Inspectio Hopper 1. Inspection for condition of hopper construction
n 2. Inspection for condition of ash cleaning
Nozzle 1. Inspection for condition of inlet nozzle
distribution plate
2. Inspection for condition of outlet baffler
channel sheet
Collecting Electrode System 1. Inspection for condition of collecting plate
2. Inspection for condition of collecting plate fixing
condition
3. Inspection for condition collecting plate rapping
hammer alignment
4. Inspection for condition collecting plate rapping
anvil shaft function
Discharge Electrode System 1. Inspection for condition of discharge emitting
wire
2. Inspection for condition of discharge emitting
Frame
3. Inspection for condition of discharge electrode
system rapping hammer alignment
4. Inspection for condition of discharge electrode
system rapping anvil shaft function
5. Inspection for condition of discharge electrode
system rapping force transit insulator and the
insulator heater
6. Inspection for condition of discharge electrode
system hanging bearing insulator
10 Day 10 Inspectio Electrical Part 1. Inspection for all heater at hopper and top Doing by
n (specially the top insulator heaters)

2. Inspection for all rapping motors and gearbox

condition,include emitting rapping / collecting
rapping

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Long Term Maintenance Report [Doc. No. -xx-xxx Rev.00]
Dry Cleaning and Inspection ESP Unit#2

No. Date Description Detail Description Remarks

3. Inspection for all rapping motors and gearbox
condition,include emitting rapping / collecting
rapping
4. Inspection for all transformer condition
included
the bushing and connect rod and insulators
5. Test resistance of discharge electrode to
collecting plates

Other Inspection for distance between the collecting

plate and emitting wire , to make sure all distance
is good enough
11 Day 11 Open test and Short test, Megger test on 1. Open test and short test to cross check all
Field, NoLoad test Transformer and control panel are still working
2. Megger to check insulation resistance of
emitting system
12 Day 12 Start up Joint with starting of plant

Friday, 31 May 2019

Install the tarpaulin at ESP’s side to prevent

ashes go further

Prepare to open all manholes

Saturday, 1 June 2019

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Long Term Maintenance Report [Doc. No. -xx-xxx Rev.00]
Dry Cleaning and Inspection ESP Unit#2

Open the middle and top position manholes

Open hopper’s manholes

Clean the manhole’s area

Open the cone ceramic’s housing and ground

it all to discharge electricity charge

Monday, 2 June 2019

Install scaffolding and prepare to dismantle

expansion joint

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Long Term Maintenance Report [Doc. No. -xx-xxx Rev.00]
Dry Cleaning and Inspection ESP Unit#2

Dismantle all expansion joint

Install Cylindrical Tarpaulin to replace the

Expansion Joint, so the ashes will fall down
right to bag of sack

Dry Clean the top position of Field 1

Tuesday, 3 June 2019

Continue the dry clean process in Field 1

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Long Term Maintenance Report [Doc. No. -xx-xxx Rev.00]
Dry Cleaning and Inspection ESP Unit#2

Dry clean in Field 2

Wednesday, 4 June 2019

Dry clean in Field 3 and 4

Sunday, 9 June 2019

Continue dry clean all Fields

Continue clean the cone ceramic housing and

Motor gearbox’s coupling on top area

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Long Term Maintenance Report [Doc. No. -xx-xxx Rev.00]
Dry Cleaning and Inspection ESP Unit#2

Monday, 10 June 2019

Continue clean the cone ceramic’s housing

and hammer motor’s casing in the middle area

Cleaning inside cone ceramic area

Tuesday, 11 June 2019

Re-install pin wheel, shaft and shaft insulator

with new one. This work was carried out
because of the initial plan is to take one set of
them from unit 2 and move to unit 1 first. But
in process there was an accident so the shaft
insulator fell down and broke . As a solution
AEP team decided to provide a new unit of
shaft insulator and re-install

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Long Term Maintenance Report [Doc. No. -xx-xxx Rev.00]
Dry Cleaning and Inspection ESP Unit#2

Install all expansion joint

Wednesday, 12 June 2019

Inspection on inside hopper area

Tag-weld on the male part of pin wheel’s shaft

and its bolt so it won’t be separated

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Long Term Maintenance Report [Doc. No. -xx-xxx Rev.00]
Dry Cleaning and Inspection ESP Unit#2

Inspection of distance between the shaft and

cone ceramic

Inspection the distance between Collecting

Plate and Emitting Electrode (Field 1 & Field 2)

Inspect the distance between Collecting Plate

and Emitting Electrode (Field 3 and Field 4)

Thursday, 13 June 2019

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Long Term Maintenance Report [Doc. No. -xx-xxx Rev.00]
Dry Cleaning and Inspection ESP Unit#2

Inspect on collecting plate’s hammer & Anvils

Inspect on collecting plates and emitting

electrodes in Field 1 and Field 2

Inspect on collecting plates and emitting

electrodes in Field 3 and Field 4

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Long Term Maintenance Report [Doc. No. -xx-xxx Rev.00]
Dry Cleaning and Inspection ESP Unit#2

Inspect of inlet screen nozzle distribution plate

Friday, 14 June 2019

Field 1 Megger Resistance Test

Field 2 Megger Resistance Test

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Long Term Maintenance Report [Doc. No. -xx-xxx Rev.00]
Dry Cleaning and Inspection ESP Unit#2

Field 3 Megger Resistance Test

Field 4 Megger Resistance Test

Because of Field 4 result was below 100 MΩ,

AEP team re-check the condition inside of field
4 and re-clean of cone ceramic. After some
time, megger test again and the picture was
result

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Long Term Maintenance Report [Doc. No. -xx-xxx Rev.00]
Dry Cleaning and Inspection ESP Unit#2

Mapping of Emitting Electrodes and Collecting Plates of Field No. 1

WALL 1 2 3 4 5

Note :
37

36

Collecting plate in good condition

35

Emitting electrode in good condition

34

33

Hammer in good condition

32

31
The condition of Collecting Plate
Bending, but based on inspection the
item is still in good condition for use

30

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 Long Term Maintenance Report [Doc. No. -xx-xxx Rev.00]
Dry Cleaning and Inspection ESP Unit#2

29

There is joint apart on collecting plate

Inlet Side
28 item

27

There is damage to the Anvil

Hammer, either the loss of bolt or
plate

26

25

24

23

22

21

20

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16 Dry Cleaning and Inspection ESP Unit#2

15

19

14

18

13

17

12

11

10

Inlet Side
7

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Dry Cleaning and Inspection ESP Unit#2

WALL
MANHOLE

Mapping of Emitting Electrodes and Collecting Plates of Field No. 2

WALL 1 2 3 4 5

Note :
37

36

Collecting plate in good condition

35

Emitting electrode in good condition

34

33

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 Long Term Maintenance Report [Doc. No. -xx-xxx Rev.00]
Dry Cleaning and Inspection ESP Unit#2

Hammer in good condition

32

31
The condition of Collecting Plate
Bending, but based on inspection the
item is still in good condition for use

30

29

There is joint apart on collecting plate

Inlet Side
28 item

27

There is damage to the Anvil

Hammer, either the loss of bolt or
plate

26

25

24

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16 Dry Cleaning and Inspection ESP Unit#2

23
15

22
14

13
21

12
20

11
19

10

18

17

4 Page 17
 Mapping of Emitting Electrodes and Collecting Plates of Field No. 3
Long Term Maintenance Report [Doc. No. -xx-xxx Rev.00]
WALL 1 2 3 4 5 Dry Cleaning and Inspection ESP Unit#2

Note :
37

36

Collecting plate in good condition

35

Emitting electrode in good condition

34

33

Hammer in good condition

32

31
The condition of Collecting Plate
Bending, but based on inspection the
item is still in good condition for use

30

29

Page 18 There is joint

damageapart
to on
thecollecting
Anvil plate
Inlet Side
28 item
Hammer, either the loss of bolt or
plate
Long Term Maintenance Report [Doc. No. -xx-xxx Rev.00]
16 Dry Cleaning and Inspection ESP Unit#2

15

14

13

12

11

10

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Dry Cleaning and Inspection ESP Unit#2

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Dry Cleaning and Inspection ESP Unit#2

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Dry Cleaning and Inspection ESP Unit#2

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