ERECTION MANUAL

OF

ELECTROSTATIC PRECIPITATOR

FOR

CLINKER COOLER

AT

M/S. GHORAHI CEMENT INDUSTRY

PVT. LTD., NEPAL
Through
M/S. HUMBOLDT WEDAG (I) PVT. LTD.

Prepared By :
ELEX (India) Pvt. Ltd.
Plot No. A 97, Road No. 18,
Wagle Estate, Thane 400 604

Project No. : 333

1
 TABLE OF CONTENTS

1.0 Salient Features of Electrostatic Precipitators

Technical Specifications of Electrostatic Precipitators

Precautions

Important Instructions Dos & Donts

- Electrostatic Precipitator

2.0 Working Principle of Electrostatic Precipitator

3.0 Constructional Features of Electrostatic Precipitator

3.1 General

3.2 Casing

3.3 Hoppers

3.4 Internals

3.4.i Gas Distribution System

3.4.ii Discharge Electrode System

3.4.iii Collecting Electrode System

3.4.iv Rappers of Discharge & Collecting Electrodes

3.5 Electrical

3.6 Inter Locks

4.0 Handling Instructions for Electrostatic Precipitator Components

5.0 Storage instructions for Electrostatic Precipitator Components

6.0 Erection Procedure for Electrostatic Precipitators

6.1 Introduction

6.2 Lay Out

6.3 Roller Bearings

2
6.4 Casing Structures & Casing Shell & Ridges

6.5 Hopper Assembly

6.6 Platform & Staircase

6.7 Gas Path Centre Line

6.8 Collecting Electrode Suspension System

6.9 Collecting Electrode

6.10 Discharge Electrode Suspension System

6.11 Discharge Electrode

6.12 Gas Distributor System

6.13 Rapping Mechanism of Collecting Electrode

6.14 Rapping Mechanism of Discharge Electrode

6.15 Roof Panels, Outer Roof, Rectifier Handling Arrangements, Insulator

Components

6.16 Insulator Housing & T/R Set

6.17 Inspection Door

6.18 Insulation

6.19 Heating Elements, Thermostats Auxiliary Control Panels,

Electronic Controllers and Interlocks

6.20 Final Checks

3
1.0 SALIENT FEATURES OF ELECTROSTATIC PRECIPITATOR

For treating of flue gases emanating from Clinker Cooler precipitators are

supplied. This precipitator is designed to have three independent

electrical fields (or systems) in the direction of the gas flow. The functional

parts (internals) and electrical accessories are being supplied for all of the

fields in the precipitators connected to Clinker Cooler. In each field, there

are number of gas ducts. A gas duct is formed by two consecutive rows of

collecting electrodes with a row of emitting electrodes midway between

them. There will be as many numbers of rows of emitting electrodes as

the gas ducts and the collecting electrode rows will be one more than the

gas duct. Each field has got its own power source and main control.

However, a common auxiliary control panel regulates the operation of all

rapping motors and thermostatically controlled electric heating elements

in all the fields.

4
 TECHNICAL DATA OF ELECTROSTATIC PRECIPITATAOR

Inlet Parameters to ESP Operating Details Design Details

Gas Volume at ESP Inlet 112091 m3/hr 310000 m3/hr

Gas Temperature 160-170 Deg. C 350 Deg. C
Outlet dust load 50 mg/Nm3 50 mg/Nm3
ESP casing design temperature / pressure 350 Deg. C Cont & 350 Deg. C Cont &
400 Deg. C for 30 min. 400 Deg. C for 30 min.
/ + <100 mm WG / + 100 mm WG

ESP SIZE / MODEL ELEX 3422/3F (14M) (with a.p.)

Number of mechanical fields in series 3

Number of gas passages 15

Field length 5.5 m

Field height 14 m

Gas passage width 400 mm

Specific collection area 80.47 m2/m3/sec

Gas Velocity 1.02 m/s

TR rating (mA / kV) / Nos. 850 mA/110 Kv 3 Nos.

Type of collecting electrode ELEX SIGMA TYPE

Discharge electrode type ELEX RIGID RS TYPE

Type of suspension arrangement 4 point

Number of support insulators per ESP 12 nos.

Number of rapper insulators per ESP 3 nos.

Type of rapping arrangement Tumbling hammer

Gas distribution arrangement At inlet (3nos) and at outlet (1no)

Drive rating of rapping for CE & DE 0.12 KW & 0.18 KW

5
 PRECAUTIONS

EXTRA CARE YOU TAKE DURING ERECTION WILL ENSURE TROUBLE FREE

OPERATION.

PROPER SEQUENCE OF ERECTION IS THE ONLY WAY FOR FAST ERECTION.

ENSURE THE PROPER STORAGE HANDLING STACKING, PRESERVATION OF

COMPONENTS AND ELECTRODES AT SITE.

REFER TO ETS ENGINEERING DEPARTMENT FOR ANY DOUBTS / DEVIATIONS IN

THE DRAWING.

ENSURE ALL ERECTION WELDING IS DONE BY CERTIFIED / QUALIFIED WELDER

ONLY.

CHECK ALL COMPONENTS FOR DEFECTS, DAMAGES AND DIMENSIONAL

DEVIATIONS AND LOG THEM BEFORE ERECTION.

TONNAGE AND QUALITY ERECTION SHOULD GO HAND IN HAND.

INSPECT ALL WELD JOINTS FOR DEFECTS AND RECTIFY THEM TO AVOID LEAKAGE

OF AIR AND SEEPAGE OF WATER.

OVERLOOKING OF MINOR DETAILS OF DRAWINGS WILL LEAD TO MAJOR REWORK.

NEVER ERECT A DAMAGED COMPONENT AND COMPROMISE ON QUALITY.

6
 IMPORTANT INSTRUCTIONS ELECTROSTATIC PRECIPITAORS DOs

01. ENSURE THE CORRECT DIMENSIONS OF THE COMPONENTS WITH THE HELP

OF DRAWING BEFORE ERECTING THEM.

02. ENSURE THE PROPER ORIENTATION OF THE ROLLER BEARINGS WITH

REFERENCE TO THE FIXED SUPPORT TO ALLOW FOR EXPANSION IN THE

CORRECT DIRECTION.

03. INSPECT ALL THE IMPORTANT DIMENSIONS OF COLLECTING ELECTRODE

SUSPENSION FRAMES AND EMITTING FRAMES FOR DIMENSIONAL

DEVIATIONS, IF ANY BEFORE LIFTING THEM TO THE POSITION.

04. STRAIGHTEN THE COLLECTING & DISCHARGE ELECTRODES BEFORE

ERECTION.

05. CHECK FOR THE CORRECT ROTATION OF RAPPING MECHANISM.

06. ENSURE THAT THE HAMMERS OF RAPPING MECHANISM HIT AT THE CENTRE

OF RAPPING BAR.

7
 IMPORTANT INSTRUCTIONS ELECTROSTATIC PRECIPITATORS DONTs

01. DO NOT ERECT DEFECTIVE / DAMAGED COMPONENTS.

02. DO NOT USE EP COMPONENTS AS TEMPORARY SUPPORTS FOR ERECTION.

03. DO NOT INTERCHANGE THE DIRECTION/POSITION OF COMPONENTS (e.g. :

LEFT TO RIGHT , RIGHT TO LEFT)

04. DO NOT STORE/STACK THE COMPONENTS IN WRONG POSITION (e.g. :

UPSIDE DOWN)

05. DO NOT ERECT THE ROLLER BEARINGS IN WRONG DIRECTION

06. DO NOT FAIL TO MARK THE CENTRE LINE OF GAS PATH IN ROOF BEAMS

BEFORE ERECTING THE COLLECTING SUSPENSION AND EMITTING

ELECTRODE FRAMES.

07. DO NOT ERECT COLLECTING ELECTRODES WITHOUT CHECKING THE

STRAIGHTNESS.

08. DO NOT ERECT EMITTING ELECTRODES WITHOUT CHECKING THE

STRAIGHTNESS.

09. DO NOT ERECT BROKEN / CRACKED INSULATORS.

10. DO NOT FORGET TO REMOVE THE TEMPORARY SUPPORTS BEFORE

COMMISSIONING.

8
2.0 WORKING PRINCIPLE OF ELECTROSTATIC PRECIPITATOR

The Electrostatic Precipitator essentially consists of two sets of electrodes called

Collecting Electrodes and Emitting Electrodes (also called Discharge

Electrodes/ RS Electrode). The collecting electrode is made up of steel sheet

pressed to a special profile and the profile bar and discharge arm of the emitting

electrode made of thin sheet are fabricated into the desired form. A

unidirectional high voltage is applied between these electrodes, connecting its

negative polarity to the emitting electrodes and the positive polarity to collecting

electrodes which are also earthed. The dust laden flue gas passes between rows

of collecting and discharge electrodes. The high voltage induces ionization of gas

molecules adjacent to the negatively charged emitting electrodes. The positive

charges of the ions created travel towards the discharge electrodes and the

negative charges towards the collecting electrodes. On their way to the collecting

electrodes, the negative charges get deposited on the dust particles. Thus the

dust particles are electrically charged. In the presence of high electric field

between the electrodes the charged dust particles experience a force which

causes the particles to move towards the collecting electrodes and finally get

deposited on them. A minor portion of the dust particles which have acquired

positive charges get deposited on the emitting electrodes also. Periodically these

are dislodged from the electrodes by a process called rapping. The particles

then fall into the hoppers at the bottom. Through dust conveying system dust

will be evacuated from hopper.

9
3.0 CONSTRUCTIONAL FEATURES OF ELECTROSTATIC PRECIPITATOR

3.1 GENERAL

The Electrostatic Precipitator may be divided into two major groups, viz.,
electrical parts and mechanical parts. The various parts of precipitator
are illustrated in the EP General Arrangement drawing for a typical
precipitator. The Assembly of Precipitator is divided into sub-groups
which are numbered in the drawing. The electrical parts comprise of high
voltage rectifier, main and auxiliary controls, switches, heaters and inter-
locks. The Mechanical parts constituting the EP, consists of the casing
and functional parts forming internals of the precipitator.

3.2 CASING

This is made up of external and internal under girders, columns, top

girders, top edge girder, main ceiling, bracing, wall panels and hoppers.
The casing rests on roller supports which are fixed to the bottom girders.
These supports allow for thermal expansion of the casing. The top girders
support the weights of internals and rectifiers, insulator housing etc.,
mounted on it. These weights are transferred through the columns of wall
panels to the structures.

3.3 HOPPERS

The hoppers are delivered to the site in prefabricated panels of suitable

size.

In order to prevent untreated gas from sneaking below the collecting

electrode each hopper is provided with sets of baffle plates suspended in
the hoppers.

3.4 INTERNALS

(i) Gas Distribution System

For optimum performance of the precipitator, it is essential that flue gas

entering the precipitator is evenly distributed over its entire cross-
sectional area.

For this purpose, rows of gas distribution plate with perforations are
located at the inlet of the casing. One set of gas distribution plates is
provided at the outlet of ESP.

Final adjustment of the gas distribution prior to commissioning of the

precipitator will be carried out by installation of deflection plates if
necessary.

10
(ii) Discharge Electrode System

The most essential part of the precipitator is the discharge (emitting)

electrode system. The discharge electrode system consists of a rigid box
like frame work which is suspended from four insulators from roof of the
precipitator. The insulators are housed in an insulator house. In order to
keep the insulators above the dew point of the gas, each insulator is
equipped with electrical heating element.

The emitting electrodes made up of IS 513 steel plates having a thickness

of 0.6 mm.

(iii) Collecting Electrode System

The collecting plates are made of steel sheets and shaped in special profile
by roll forming. These profile of the collecting plate lend mechanical
rigidity to it and also limit re-entrainment of collected dust during
rapping. The collecting plates of 500 mm width and 14 m length are
hung from the top.

(iv) Rappers for Discharge and Collecting Electrodes

During electrostatic precipitation, a fraction of the dust will be collected

on the discharge electrodes. This suppresses the corona, which is the
source of ionization. It is therefore necessary to rap clean the discharge
electrodes occasionally. This is done with a rapping system employing
tumbling hammers which are mounted on a horizontal shaft in a
staggered fashion. These hammers hit the specially designed anvil plate
located at the top of the supporting traverse of Discharge frame to which
the discharge electrode is hanged. In this manner, the vibrations
generated by the hammers are transmitted to the discharge electrodes.

Each collecting plate of 500 mm width is hung using a suspension pin on

the suspension bar eccentrically. In this manner, the highest possible
energy is transferred to the collecting plate when the tumbling hammer
hits the corresponding rapping bar. The tumbling hammers are mounted
on a horizontal shaft in a staggered fashion, with one hammer for each
rapping bar. As the shaft rotates slowly, each of the hammers in turn
over balances and tumbles, hitting its associated rapping bar. The
rapping bar transmits the blow simultaneously to all the collecting plates
in one row because of their direct contact with the rapping bar. The shaft
is connected to a geared motor mounted on the outside of the casing.

11
 The frequency of rapping is adjusted by controlling the operation of the
geared motor by means of programmer, mounted in the auxiliary control
panel.

3.5 Electrical

The Precipitator is powered by high voltage Transformer rectifier mounted

on the roof. The negative polarity of the rectifier transformer is connected
to the emitting system through high voltage switch and bare conductor.
The electronic controller regulating the power output of the rectifier is
located inside the control room. An auxiliary control panel containing
programmer, relays, switches, etc., necessary for regulation of the
operation of rapping motors and heaters is also supplied and located
inside the control room.

3.6 Interlock

Electrostatic Precipitator is a high voltage equipment. Safety of the

operating personnel and protection of the equipment are ensured by an
interlocking system. These interlocks are provided on inspection doors of
the casing, hoppers, insulation roof and T/R sets.

The interlocking system is designed such that access inside the

precipitator can be gained only after switching off the power supply to the
precipitator and grounding the relevant fields.

12
4.0 HANDLING INSTRUCTIONS FOR ELECTROSTATIC PRECIPITATOR
COMPONENTS

(i) Do not use door handles and bolt holes for lifting the components.

(for Example :- Insulator housing, disconnecting switches, inspection

doors etc.)

(ii) Use stiffening beams for lifting slender members like roof panels, wall
panels and roof beams etc., to avoid distortion.

(iii) Do not use metal ropes for lifting collecting electrodes. Use only manila
ropes and lifting beams to avoid damage to the electrodes.

(iv) If top entry method is adopted, lift collecting electrodes to the top of
electrostatic precipitator in full packs by lifting beams
Open the packs at the top and the collecting electrode may be taken up
one by one.

(v) Handle emitting electrodes such that the surface does not get any scratch
or pittings.

13
5.0 STORAGE INSTRUCTIONS FOR ELECTROSTATIC PRECIPITATOR
COMPONENTS

 Stack all components well above the ground level to protect against water,
dust and soiling. Minimum height above the ground level shall be 300 mm.

 Never stack a component upside down.

 Protect the machined components (machined portions) like suspension tube,

protection tube, connecting rods, shafts, pin wheel, ratchet and other
machined items against rusting and damage during storage. Ensure that the
threaded portions are covered properly to avoid damage.

 Girders, roof beams, columns and hopper ridges are to be stored in a

horizontal plane by providing supports at sufficient intervals to avoid any
bending and twisting.

 Casing panels hot and cold roof panels are to be stored on a horizontal plane
one over the other. While stacking sliding of one panel over the other should
be prevented by providing suitable supports.

 All suspension frames of collecting electrodes, frame of emitting rapping bars,

anvils etc., received in the packed condition shall be stored in a horizontal
plane. Not more than 3 packages are to be stacked one over the other.
Damaged packings are to rectified before stacking.

 High voltage transformer rectifiers, control cubicles, Auxiliary control panels,

LT boards, interlocks, High voltage insulators, heating elements,
thermostats, roller bearings, carbon bushes, drive motors are to be kept in a
closed storage to avoid rusting due to moisture and to protect against
pilferage.

 Collecting electrodes, discharge electrodes, gas distribution screen sheets,

insulator housing are to be kept in a semi closed storage to protect against
rust and damage.

 Stair beams, supporting beams, vertical beams are to be stacked in a

horizontal plane with supports at proper interval.

 Ensure that all the components of the High Voltage rectifier panels and
Auxiliary control panels (if provided) are perfectly closed to prevent damages
to cables by rodents and termites.

 Keep the insulators over soft material to avoid any damage. Do not stack any
other material over the insulator and keep the insulator sufficiently away
from other materials so as to avoid the damage/cracks due to falling of
metallic parts.

14
 The high voltage transformer rectifiers are to be stored in a fire proof
enclosure and should be well guarded from fire hazards.

 On receipt of the electrical components/equipments verify carefully

damages/pilferages. Necessary action for replacement/repair/insurance
claim shall be initiated within a month. After inspection, ensure a safe
storage.

 Emitting electrode boxes shall be kept in a closed storage and shall be

opened only when erection is taken up.

COMPONENTS REQUIRING COMPONENTS REQUIRING

CLOSED STORAGE SEMI-CLOSED STORAGE

Roller Bearings Collecting Electrodes

Support Insulators Suspension tubes
SKF Bearings Shafts
Emitting Electrodes Plain bearings
Packing rope Sleeves
All fasteners Lifting rods
Rapping Motors Couplings
Rapping Insulators Pin wheel
High voltage transformer rectifiers Foundation bolts
Electronic controllers Insulator housing
Auxiliary control panels
Interlocks
Heating elements
Thermostats
Earthing cables
Earthing rods
Pulley block

15
6.0 ERECTION PROCEDURE FOR ELECTROSTATIC PRECIPITATOR

6.1 Introduction

For proper and efficient performance of the electrostatic precipitator, it is

essential that the voltage distance between the collecting electrodes and
emitting electrodes is maintained. Unless the erection is carried out in a
sequential order and corrections are done stage by stage, the inter-
electrode gap cannot be maintained within the given tolerance.

The applicable drawings may be referred.

6.2 Layout

Refer : - ESP Foundation plan

- General arrangement drawing

(i) Check the foundation of electrostatic precipitator columns

(ii) Mark the central line of the precipitators.

(iii) Check, verify and log the measurements between the central line of the
side column pedestal. Ensure that this is within the tolerance of + 10 mm.

(iv) Measure and verify the distance between the central line of last row of
nearest building column pedestals and the fixed support of electrostatic
precipitator column pedestals. Ensure this is within the tolerance of + 10
mm.

(v) With fixed supports row of electrostatic precipitator column pedestal as

reference, measure and log the distance between the centers of the
subsequent column pedestals on both axes. Ensure that this is within
the tolerance of + 10 mm.

6.3 Roller Bearings

Refer - Arrangement drawing.

(i) Place the bearings on top of steel insert plate. Ensure proper leveling.

(ii) Align the bearings with respect to the fix foot. Care should be taken to
ensure that the direction of the movement is along a line radiating from
the fix foot.

(iii) After checking of level and alignment, weld bottom plate of bearing
assembly with support column insert plate.

(iv) Do not remove any temporary locks now. The locks are to be removed only
after the ESP has been completely erected and ready for commissioning.
16
(v) Log all the measurement.

6.4 Casing, Structures, Casing shell and Ridges

Refer : - - Casing Assembly drawing of electrostatic precipitator

(i) Place external and internal bottom girder as per the drawings.

(ii) Check the dimensions as per drawing. The diagonal difference shall be
within 10 mm.

(iii) Complete the welding as per drawing

(iv) Place all the columns on the bottom girder as per the drawing and then
top external and internal girder, as per the drawing, and then place all the
pipe bracings as per the drawing. Also fix the top edge girder and beam of
the main ceiling on top girder as per the drawing.

(vi) Check the verticality on both axes of the columns within 1 mm per metre
height limited to 10 mm on the total height. Also check the level of top
girder and diagonals at top of the girder. The diagonal distance must be
within 10mm.

(vii) Weld the column base with the bottom girder, top girders, with columns,
pipe bracing with the top girder and column, and edge girder with the top
girder as per the drawing. to the top plates of supports as shown in the
drawing.

(viii) Erect casing panel from bottom to top.

(xi) Check the fitment of the casing panel and weld the same as per drawing.

(xiv) If facility is available assemble the inlet cone and outlet cone at ground
level or piece by piece erect the same at inlet and outlet of the electrostatic
precipitator. After proper fitment weld the same to make EP leak proof.

NOTE : IT IS IMPORTANT TO NOTE THAT ELECTROSTATIC PRECIPITATOR

SHOULD BE LEAK PROOF IN ALL RESPECT SO PROPER WELDING USING
A QUALIFIED WELDER AND SPECIFIED ELECTRODE MUST BE USED
DURING WELDING. TH0ROUGH WELDING CHECKING SHOULD BE DONE
AND IF REQUIRED WELDING SHOULD BE TESTED AS PER STANDARDS
BY AUTHROIZED TESTING AGENCY.

17
6.5 Hopper Assembly

Refer Assembly drawing.

Hopper lower & upper part.

(i) Pre-assemble the hopper on the ground. Match the total dimensions of a
particular hopper with the corresponding hopper opening dimension.
Complete the welding of the hopper. Fix and weld the inspection doors of
the hoppers.

(ii) Lift the hopper assembly and position it keeping the orientation of the
hopper door as per the General Arrangement drawing

(iii) Support the hopper assembly with the cleats.

(iv) Level the hopper bottom flange by spirit level and weld ensuring the
hopper bottom elevation as per the GA drawing.

(v) Seal weld the hopper assembly.

However before erection/ assembly of the hopper, care should be taken

about, hopper baffle plate otherwise after erection it will be difficult to fix
the hopper baffle, in its position

NOTE: In most of the cases collecting electrode and discharge electrode are lifted
through the bottom of the ESP so hopper is to be erected after the
completion of the internals of the ESP Hopper

6.6 Platforms and Staircase

Refer : - Relevant drawings of electrostatic precipitator.

Erect brackets, stairways, platforms with railings, leaving proper provision

for thermal expansion as shown in the drawing.

6.7 Gas path center line (GPCL)

Refer : - Roof panels assembly drawing.

Insulator supporting panels drawing

(i) Gas path Centre Line (GPCL) is a line which passes through the center of
the effective width of each pass. All internals are mounted only with
reference to these lines.

(ii) Mark the GPCL of the pass on the top flange of the first and last
transverse roof beams or the ends of longitudinal roof beam as the case
may be.

18
(iii) Stretch a twine between the markings and transfer the GPCL on all other
roof beam top flanges. Do not mark the GPCL on each roof beam by taking
separate measurements.

(iv) Punch all the GPCL markings on roof beams for reference.

(v) Transfer the GPCL from the top flange to the bottom flange of the roof
beam.

6.8 Collecting Electrode Suspension System

Refer : - Collecting electrode suspension arrangement drawing.

(i) The collecting electrode suspension is one of the vital components that
decide the effective voltage distance. Any deviation either in dimension of
the frames or in the disposition of frames with reference to the GPCL
would affect the performance of the electrostatic precipitator seriously.

(ii) Before lifting the suspension frame following work is to be completed

(a) Check straightness of the suspension bar as per the drawing.

(b) Check the gap between the channels of the suspension bar

(c) Check the welding of the suspension bar

(d) Fix guide finger on the basis of GPCL

(e) Fix guide angle, block for guide angle, bracket for guide angle,
walkway and guide and deflection plate

(f) Check the diagonals after positioning all suspension bar

(g) Place the rapping bar on the guide bar

(iii) Place the suspension bar as per the drawing, and check the position with
the guide finger through plumb.

(iv) Check the diagonals after positioning all suspension bar

(v) Place the rapping bar on the guide finger

a) Check the straightness of the rapping bar as per drawing.

b) Also check the welding of nuts and bolts of the rapping bar.

19
6.9 Collecting Electrode

Refer : - Collecting Electrode assembly drawings

(i) There are many ways to lift the collecting electrodes to the desired position
so as to suspend them from the suspension bar. The method of lifting
brought into effect depends on the site condition:

a) From top

b) From bottom before hopper erection.

(ii) Suspension of collecting electrodes from the suspension bar can be

started either from one of the ends or from the middle, but it is advisable
to start the suspension from one of the ends and finish at the other end.

(iii) Fix the guide plates during lifting of the collecting plates.

6.10 Discharge Electrode Suspension System

Refer : - Suspension of Discharge Frame drawing.

(i) Place the protection tube with insulator housing on the main ceiling with
respect to the GPCL as per the drawing.

(ii) Place the discharge electrode suspension frame, traverse and RS-
Electrode, supporting traverse with respect to GPCL and protection tube.
Fix the entire assembly with temporary support.

(iii) Check for the alignment of (i) and (ii) and weld the protection tube with
the main ceiling.

6.11 Discharge Electrodes

Refer : - Suspension of Discharge electrodes Assembly Drawings

(i) Check the straightness of discharge electrodes and keep the straightness
within 2mm maximum.

(ii) Check the welding of coupling of R.S. electrode.

(iii) Fix the R.S. Electrode top and bottom part by bolt and nut.

(iv) Fix the discharge electrode with supporting traverse and stabilizing bar.

20
(v) Fix guide bar and connecting piece. Also fix the fixing traverse, stabilizing
traverse, and shackle as per the drawings.

(vi) Check the distance between the discharge electrode and collecting
electrode.

(vii) Place the supporting insulator on the protection tube and the insulator
cover on the supporting insulator. Put gasket in between the insulator
cover and supporting insulator and protection tube.

(viii) Put suspension tube, suspension link, nut and ball cup as per the
drawing.

(ix) Tightening all the nuts together/ one by one slowly so that the total load
of the discharge frame including that of the discharge electrode is
transferred on the supporting insulator slowly and hang on it rigidly.

6.12 Gas Distributor System

Refer : - Gas Distributor Assembly drawing

(i) Hook the screen sheets through hanger already fixed with the supporting
cone.

(ii) Mount the angle traverse and tie rods and keep all the dimension as per
the drawing.

(iii) Erect the outlet screen at outlet.

(iv) Check the verticality of the screen sheets with plumb.

(v) Ensure that a minimum gap of 100 mm between the bottom edge of
screen sheets and front wall surface.

(vi) It is advisable to erect the inlet GD screen before arranging the collecting
electrodes in the first field.

21
6.13 Rapping Mechanism for Collecting Electrodes

Refer : Rapping System for Collecting Electrode drawing

a) Make the centre line of rapping bars horizontal.

b) Place all bearing block & bracket as well as roller & bushing as per the
drawing.

c) Place the shaft on roller and bushing along with coupling/ bearing, after
straightening the shaft and removing the rust from the shaft surface. The
distance between the center line of the shaft and the center line of the
rapping bar anvil should be as per drawing. Also make one hole in the
casing so that shaft can pass through the casing, with its drive placed
outside the casing.

d) Fix bushing ( Packing Box) from outside the casing to make it leak proof

e) Support for drive should be fixed outside the casing as per the drawing,
also check the physical height of the Collecting Electrode Geared Motor
and keep some packing(bed plates) provision for easy alignment.

f) Fix all the rapping hammer on the shaft in such a fashion that each
hammer maintains a uniform angle of separation between them. Also
check the center line of rapping hammer, and the center line of rapping
bar anvil should match vertically.

g) Fix the coupling and gearing motor.

h) Also fix in the first field GD screen rapping arrangement which includes
hammer, GD rapping bar etc. as per drawing.

NOTE : Mark the correct direction of rotation of the shaft and fix the
Direction Marker at a prominent place on the gear unit. Paint a caution
DONT REVERSE THE ROTATION on the bracket. Reverse rotation will
cause serious damage to the rapping bar, rapping bar guide and shaft and
disrupt the alignment of the electrodes.

6.14 Rapping Mechanism for Discharge Electrodes

Refer : Rapping System for Discharge Electrode drawing

a) Place all bearing block & bracket as well as roller & bushing as per
drawing

22
b) Place the shaft on roller and bushing along with pin wheel, lever and
coupling after, straightening the shaft and removing the rust from the
shaft surface. The distance between the center line of the shaft and the
center line of the anvil should be as per the drawing.

c) Fix the geared motor along with eccentric and swing bearing also put the
gasket in between insulator housing and geared motor.

d) Fix the ratchet, along with lifting rod and rapping insulator and adjust
the lifting rod, lever and ratchet in such a fashion that, when geared
motor runs, pin wheel should rotate the shaft in a proper manner. Thrust
bearing is also to be fixed properly as its keeps the axis of rotation of the
pin wheel constant.

NOTE : Please maintain all the dimensions as per the drawings, otherwise it
will be difficult to maintain the rapping mechanism of the discharge
electrode in working condition.

6.15 Roof Panels, Outer Roof, Rectifier Handling Arrangements, Insulator

Components.

(i) Compete the erection of balance roof panels. Welding shall be leak proof.

(ii) Also take care that the T/R set handling system, while erecting main
ceiling and insulator house roof .

6.16 Insulator House, T/R set and Bus Coupler.

(i) Insulator house wall and root are to be fixed as per drawing

(ii) T/R set is to be placed and connected with the Bus Coupler as per
drawing

(iii) The Bus Coupler and HT Connection to be erected as per drawing

6.17 Inspection Doors

(i) All inspection doors for hopper, casing and roof are to be fixed and seal
welded per drawing. Ensure that there shall be no projection inside the
hopper/the casing. Ensure that the doors close freely. Bolt the earthing
cables on to the door and the flange.

23
6.18 Insulation :

(i) Weld the fixing pins on the surfaces to be insulated.

(ii) Insert and tack weld the retainers on the fixing pin, so as to retain the
insulation, just upto the height of the stiffener.

(iii) Place the mineral wool mattress and press them on to the pins.

(iv) Sew the wire nettings of the mattresses at the ends by sewing wires.

(v) Tie the binding wires across the fixing pins below the retainers.

(vi) Fix the casing support to the retainers by using the self tapping screws.

(vii) Lay the outer casings over the casing supports by screwing self tapping
screws.

(viii) Take care while lapping the outer casing that no rain water enters into the
insulation.

6.19 Heating Elements, Thermostats Auxiliary Control Panels, Electronic

Controllers and Interlocks

Refer : - Insulator housing assembly drawing.

- Interlocking system and interlocking arrangement drawing.

(iv) Heaters :-

Mount the support insulator heaters. Ensure that the heaters sit
properly and concentric to the support insulators

6.20 Final Checks :

(i) Ensure that the walls roof and hopper walls do not have any holes.

(ii) Ensure that all temporary stays, supports, etc., used during erection are
removed.

(iii) Ensure that the nuts and bolts in the rapping mechanism as well as on
the emitting frames are locked by tack welding, after trial run of 48 hrs
and clearance of the commissioning engineer.

(iv) Ensure that no welding beads, projections or sharp edges are left in the
vicinity where flash-overs will occur during operation. Check all critical
dimension and compare the same with log dimension.

24
(v) Ensure that the earthing handles are welded on to the emitting framework
nearer to the inspection door. Ensure that all earthing cables are properly
fitted at doors and connections.

(vi) Ensure all gear boxes are filled with oil.

(vii) Remove all foreign materials like welding rods, cut bits, wooden planks
etc., from inside the EP.

25