Esp e

.
Electrostatic Precipitator
Type E
Erection of filter casing and internal systems

Approved date: 30-May-2008
Created by: HFB
Approved by: HFR
Doc. No.
52221-06
Electrostatic precipitator
52221-06
List of contents:
Page:
General ....................................................................................................... 4
Welding regulations ...................................................................................... 4
Preparations work ......................................................................................... 4

3.1
Manual definitions ......................................................................................... 4
3.2
Documentation .............................................................................................. 4
3.3
Receiving and handling of equipment ............................................................... 5
3.4
Storing and uncrating .................................................................................... 5
3.5
Position control ............................................................................................. 5
3.6
Control measurement forms for profiles ............................................................ 5
Planning of erection ...................................................................................... 6
4
5
6
7
Erection of filter casing .................................................................................. 6

5.1
Support ........................................................................................................ 6
5.2
Assembly and welding of portals ...................................................................... 6
5.3
Erection of first portals ................................................................................... 7
5.4
Portals with centre column ............................................................................. 10
5.5
Erection of other portals ................................................................................ 10
5.6
Control ........................................................................................................11
5.7
Erection of hopper ........................................................................................ 11
5.8
Welding of filter casing .................................................................................. 14
Inlet and outlet ........................................................................................... 15
Erection of internal systems .......................................................................... 16

7.1
Control and establishing of centre line ............................................................. 16
7.2
Erection of guide angle and guide iron ............................................................. 16
7.3
Before erection of collecting plates .................................................................. 18
7.4
Erection of collecting plates, top rapping.......................................................... 20
7.5
Erection of collecting plates, bottom rapping .................................................... 22
7.6
Installation of discharge frames ...................................................................... 23
7.7
Discharge system with vertical rapping: .......................................................... 23
7.8
Discharge system with horizontal rapping ........................................................ 25
7.9
Erection of rapping gears, top rapping ............................................................. 27
7.10 Erection of discharge system .......................................................................... 34
7.11 Cutting loose, final control of spacing and securing of bolts ................................ 35
7.12 Final ........................................................................................................... 35
Roof plates ................................................................................................. 37
Inspection doors and hatches ......................................................................... 37
10 Completion of filter casing erection ................................................................. 37

11 Preparation of precipitator for operation .......................................................... 37
12 Legend for principle drawing .......................................................................... 39
2/40
The information transmitted by this document is the proprietary and confidential property of FLSmidth
and may not be duplicated, disclosed or utilized without written consent from FLSmidth.
52221-06
Reference documentation
Manuals
In the text there are references to:
Manual for control forms

Manual concerning erection of insulation
Erection manual for steel support/roller
bearings/journal bearings
Operation and maintenance manual
Manual for planning of erection
General workshop instructions
Operation and maintenance manual for geared motors
Drawings and parts lists

In the text there are references to:
Dimension and load drawing

Erection drawing for filter casing
Dimension drawings
Welding of portals
Assembly drawing of roof
Assembly drawing for inlet
Assembly drawing for outlet
Assembly drawing of collecting system
Assembly drawing of discharge system
Installation drawing of collecting and discharge systems
Assembly drawing of gas distribution screen (inlet)
Assembly drawing of gas distribution screen (outlet)
Erection instructions drawing for cutout for rapping devices and inspection hatches
Position of HV equipment on roof
Insulation
Drive for discharge rappers
Drive for collecting rappers
Standard parts for discharge system
3/40
52221-06
1 General
The
electrostatic precipitator is designed to clean flue gasses from

incinerators
power station boilers

clinker coolers
cement kilns and raw mills

etc.
Function
Dust particles are cleaned from the flue gasses by
electric charging of the dust particles, collecting and then
mechanical shaking with rapping device
removal with mechanical transport equipment

Design
The filter can be designed with one or more chambers, each with one or more sections, with
separate electric functioning. The filter is bedded on either roller bearings or a pendular
support to allow for thermal expansion.
Dimensioning
Dimensioning of the filter for pressure and temperature, together with the design of the inlet
and outlet, hopper and any prechamber, depends on the process and the actual plant
conditions.
2 Welding regulations
The welding work must be done as stipulated in the "General Workshop Instructions".
Local regulations
The welding method and filler metal, together with execution regulations and control of welds,
must be in accordance with the standard regulations for first-class work which apply locally.
FLS Airtech regulations
Where such regulations do not exist, welds should be executed by agreement with FLS
Airtech.
3 Preparations work
3.1
Manual definitions
Overall installation divides naturally into mechanical, casing and internal parts, electrical and insulation sections.
Local conditions
These erection instructions and their order may be departed from where local
conditions, filter size, etc., make it expedient to do so.
3.2
Documentation
Control and use

The documentation summary in the main parts list should be used to check that the
entire erection documentation is present.
Users of the erection documentation must familiarise themselves with its structure and
application.
4/40
52221-06
Prioritization
In the event of discrepancies between this manual and the rest of the erection
documentation, it should be pointed out that this manual is general and that actual
dimensions and tolerances are always shown on the installation drawings.
3.3
Receiving and handling of equipment
Control
As the parts are received check the quantity and the quality.
In case the quantity and quality is incorrect according to the erection documentation it
must be reported immediately to the main office. Also in case of shipping damage the
office must be informed.
Handling
Lifting and transport of the equipment must adhere to possible instructions on the
equipment. These instruction may be attached or painted to the parts or the packing.
3.4
Storing and uncrating
Electrical
The electrical equipment must be placed in dry storage rooms immediately upon
receipt.
Insulation
Insulation material must be stored in such a way that it is protected from the weather.
Mechanical
The mechanical equipment which is delivered in sealed crates must be protected from
the weather.
Depending on the storage time and actual climatic conditions, the rest of the
mechanical equipment should be afforded reasonable protection from the weather.
3.5
Position control
Plant conditions
Check that the dimension and load drawing, is in accordance with the actual plant
conditions with regard to:
3.6
inlet and outlet

drive and turning station
inspection hatches
rapping drive stations
dust outlet and connected transport equipment
Control measurement forms for profiles
Control form
Immediately after the receipt of equipment for the filter casing and internal equipment,
a set of control measurement forms for profiles must be completed and sent to FLS
Airtech for approval.
5/40
52221-06
4 Planning of erection
Planning should be done as described in the manual for planning of erection.
5 Erection of filter casing

See figs. 1, 2 and 3.
5.1
Support
See erection manual for steel support/roller bearings/journal bearings.

Before erection of the filter casing is started, the pendular support/bearing support
must be prepared in accordance with the instructions in the relevant documentation.
General precautions
Casing stability
The precipitator structure is not fully stable against wind and earthquake forces, until
all internals and all casing elements, including hoppers and in- and outlet, are
mounted.
Until all equipment is mounted, the precipitator must be stabilized, e.g. with wires
connecting to firm anchor points.
5.2
Assembly and welding of portals
Base
Place the columns, roof beam and bottom beam on a firm base and block up to make
them level.
Control
Bolt the portal together and check that the transverse, longitudinal and diagonal
dimensions are correct.
If the actual transverse and longitudinal dimensions deviate from the drawing
dimensions by more than 10 mm, FLS Airtech must be contacted. They will then
suggest a solution with regard to how the situation should be remedied.
Welding
After final control of the individual portals, they should be welded together in
accordance with ref. doc. and the appropriate welding control carried out.
Stays
Place the two upper stays and two lower stays and weld in accordance with ref. doc.
Welding of portals.
Adjustment
On the finished portals, check that the distance between the support points agrees with
the corresponding dimensions on the pendular support/bearing support.
Control forms
Mark the centre of roof beams and bottom beams for subsequent control of the erected
portals, and for use when erecting the internal equipment.
Complete a measurement control form for the portals.
6/40
52221-06
5.3
Erection of first portals
See fig. 1.
Preparations
Before erection of the first portals is commenced, the necessary safety measures must
be taken to ensure that dangerous situations do not occur during the work, and that
current safety regulations are complied with.
Stability
The structure is unstable until the entire filter casing, including bottom hopper, has
been installed and welded, and must therefore be protected from the effects of wind
(windy weather), e.g. with wires.
Fittings and strapping
Weld a fitting with holes for guys on the inside of the first portal.
Carefully strap the first portal, which must stand on the fixed foot.
In the case of the pendular support, the first portal must be raised by the fixed part of
the support.
Fit the guys and lift the portal until it is hanging precisely above the foot and bearing.
Lower the portal into place, but leave it hanging in the strap.
Erection
Hold the portal by the bearings using the guides and secure in a vertical position using
the guy strainers.
Use the marked centre points on the roof and bottom beams to check whether the
portal is vertical.
Release the lifting gear when the portal is secure and vertical.
Internals
If it is possible, install the guide angles and the guide irons for the supporting beam on
the portals before they are raised, see chapter 7.
7/40
52221-06
Erection of filter casing
POS. 1:
POS. 2:
POS. 3:
POS. 4:
8/40
FIG. 1
Assembly and welding of portals on the ground.

Assembly and welding of pyramid bottom hopper (A),
and inlet and outlet (B).
Positioning of foundation plates on concrete support (A),
or on steel support (B).
Erection of first portal and centre marking on roof beam
and bottom beam.
52221-06
POS.
POS.
POS.
POS.
5:
6:
7:
8:
Erection
Erection
Erection
Erection
of
of
of
of
FIG. 2
portals.
stabilizing beams.
casing.
bottom hopper.
9/40
52221-06
POS. 9:
POS. 10:
5.4
FIG. 3
Erection of inlet and outlet.

Finished filter casing.
Portals with centre column
If an entire portal, including centre column, cannot be raised with the existing lifting
gear, assemble and raise a part portal.
Erection
Assemble and weld the part portal from an upright column, a centre column and a half
roof beam and bottom beam.
Assemble and weld the other column with the other half roof beam and bottom beam,
raise and weld to the erected part portal. Check the diagonal dimensions, main
dimensions and vertical position of the finished portal.
5.5
Erection of other portals
See fig. 2.
Portals
Erect the other portal as specified for the first portal, but without guys.
Hold the portal in its final position either by connecting it to the previous portal with at
least three angle bars welded between the portals, or by installing the side wall plates.
Side wall plates
Lift the side wall plate up until the top edge is horizontal and level with the top of the
roof beams, suspend it on the roof beams in the correct position and tack-weld the
plate to the outside of the column.
Erect and tack-weld the side plates on both sides. Check that the portal is still standing
correctly.
Continue in the same way with the other portals and side plates.
10/40
52221-06
Control
Tack-weld the side wall plates to the columns. Check that the portal is still standing
correctly. Continue in the same way with the other portal and side wall plates.
5.6
Control
The roof beams must be horizontal and the column must be vertical. Use a plumb-line
to check whether the midpoints of the roof and hopper beams are on the same vertical
plane. If the midpoints are on the same vertical plane, the bearings are on the same
horizontal plane, the diagonal dimensions of the portals are the same and the roof
beams are horizontal. If this is the case, erection has been done correctly.
Adjustment
If the midpoints are not on the same vertical plane, a deviation of up to max. 10 mm
can be accepted. Transfer the centre mark on the hopper beams vertically to the roof
beams, plot a new "corrected" midpoint, and use it as the basis for further erection.
Before erection continues, errors greater than the 10 mm specified must be corrected.
5.7
Erection of hopper
Longitudinal hopper
Partition plates
Tack-weld the partition plates to the plate on the bottom of the bottom beams. The
partition plate can be shifted into the correct position.
Side wall plates
Fit the side wall plates below the filter with the inside facing up.
Weld a lifting eye in position approx. 100 mm vertically above the plate's centre of
gravity (midpoint).
This makes it possible to lift the plate into the correct slanting position.
Lift the side plate into place and tack-weld it to the side wall of the casing and the
partition plates.
The plates can be shifted longitudinally.
Control
Check the overall length of the hopper before the final plate is welded into place on
each side.
Gable end trough
Erect the gables at each end of the hopper. Erect the trough for drag chain or screw
conveyor.
Preassembly
If the hopper is preassembled, it is necessary to check if the cut outs for the side
columns are big enough to let the hopper in between the precipitator support.
Pyramid hopper
See fig. 4.
If possible, weld hopper together on the ground and erect in one piece:
Pull gable walls together, approx. 150 mm. Fig. 4.3.
Pull side wall, outer side, toward centre of the hopper, approx. 500 mm. Fig. 4.4.
Fasten stay inside the hopper to fix the walls in this position. Fig. 4.5
When the hopper is prepared in this way, it can be either lowered into position from
below, downwards or from the side in between the portals.
11/40
52221-06
It might be necessary to load the pyramid hoppers in between the pendular support
before placing the portals.
Control
Check the final position of the pyramid hoppers according to main dimension drawing,
and documentation for ash transport system.
12/40
52221-06
Pyramid hoppers
POS.
POS.
POS.
POS.
POS.
FIG. 4
1, 2:
3:
4:
5:
6:
Assembly and welding of pyramid hopper on the ground.

Pull gable walls together.
Pull side wall, on the side, towards centre.
Secure with wire or stays.
Pyramid hopper ready for erection.
13/40
52221-06
5.8
Welding of filter casing
See "General Workshop Instructions".

The following special details should be emphasised:
Important details
Fully weld the sealing plates at the bottom beams.
Intermittent-weld of the filter housing from the outside and make gas-tight welds
in accordance with the reference documentation.
Do the intermittent-welds opposite the gas-tight joint first. This prevents the joint
from bending when full welding is done from the opposite side.
Where two plates are butted together without flanges, make a gas-tight weld from
one side with a 2 mm gap between the plates.
Weld horizontal joints from the centre out towards the sides.
Weld vertical joints of less than 4 metres in length from the centre down first, then
from the top down to the centre.
Divide vertical joints of more than 4 metres in length into welds of approx. 2
metres in length.
If a joint bends, straighten it with spot heat from the outside of the bend.
Gas-tight result
Ultimately, the filter casing must be gas-tigh throughout.
14/40
52221-06
6 Inlet and outlet

See fig. 3.
Assemble and erection
If enough lifting gear is available, assemble and weld the inlet and weld outlet on a horizontal
base.
Check height, width and diagonal dimensions. Weld with a intermittent-weld seam on the
outside and a full welding on the inside.
Lift the finished inlet or outlet into place. Weld in place with a intermittent weld on the outside
and a full weld on the inside.
If there are gas distribution screens in the inlet or outlet, it is a good idea to erect them before
the inlet/outlet are mounted on the filter casing.
When the gas distribution screen is erected in the inlet/outlet before it is mounted on the filter
casing, adequate stiffening must be provided to avoid damage to the gas distribution screens.
Gas distribution screen
To facilitate erection of the gas distribution screens, it is a good idea to install the suspension
hooks in the top plate while it is still on the ground.
15/40
52221-06
7 Erection of internal systems

General precautions
Wind damage to collecting plates
As soon as any collecting plates have been mounted, the filter apertures must be kept
covered, to prevent damage to the plates from being set in motion by wind or draught.
Use tarpaulins or similar.
Stability of roof beams
If internals are installed when no roof plates are mounted, the top flanges of the roof beams
may become unstable and deflect horizontally. This must be prevented, for instance by
mounting two heavy angle irons pr. beam with heavy tack welds. Space angle irons evenly to
reduce the free length of the roof beam top flange to one third.
Alternatively the free length may be reduced to one third by connecting the roof beam top
flanges to the casing sidewalls using temporary flat bars, allowing better access for mounting
of internals.
7.1
Control and establishing of centre line
Control
The precipitator
documentation.
casing
must
be
checked
in
accordance
with
the
reference
Transversely and longitudinally the casing must be square.

Each field must be checked. The checking is carried out by the use of a transit or a
plumb line. Transverse and longitudinal deviation between the vertical position of the
bottom and the roof must not be greater than 10 mm.
Based upon these centre lines the internal equipment is installed.
7.2
Erection of guide angle and guide iron
See fig. 5.
Install the centre guide angle on the roof beam in the front and the centre guide iron in
the back of the field. The guides are aligned in accordance with the established centre
line.
With the centre line as base line, the individual guide angles and guide irons are
aligned, and tack-welded to the roof beam.
To avoid accumulation of measuring errors all measurements must be taken from the
centre line.
This is best done by stretching a measuring tape transversely on the roof beam, and fix
it to the centre line.
16/40
52221-06
Erection of supporting beams for collecting plates
POS.
POS.
POS.
POS.
POS.
POS.
POS.
1:
2:
3:
4:
5:
6:
7:
FIG. 5
Roof beam, end wall.

Supporting angle.
Gas direction.
Fixed end of the supporting beam.
Free end of the supporting beam.
Measurement according to drawing.
Measurement always to centre line.
17/40
52221-06
7.3
Before erection of collecting plates
See fig 6.
Preparations
The installation of the collecting plates must be organized in a orderly fashion. Thereby
the resources, time and quality can be ascertained.
The installation of the collecting plates and the straightness of same is crucial. The
compliance with the correct spacing between the collecting and discharge system is an
important factor for the performance of the precipitator.
Inspection
Well before the installation of the collecting plates they have to be inspected. Look for
shipping damage and straightness of the plates.
Before prestraightening
If the plates are delivered without shipping damage and an inspection of the first
hung plates indicates a good straightness, it is not necessary to prestraighten the
plates.
Prestraightening
If the plates do not comply with the above a prestraightening will pay off. See next
chapter: Straightening of collecting plates.
Installation method
The installation of the collecting plates is in the most cases done most
effectively through the roof. If this method due to practical circumstances is not
feasible, contact the main office for alternative methods.
Erection fixture
When the collecting plates are to be installed through the roof an installation jig is
needed. Preferable the jig should hold whole rows of collecting plates. The design must
be made on site according to the method of erection. See chapters 7.4 and 7.4a.
Rust protection
It is not necessary to remove the rust protection oil on the collecting plates. Except for
the areas specified on drawings.
Prestraightening of collecting plates
Straightening fixture
If any prestraightening of the collecting plates is required, it is advantageous to do this
outside the precipitator. It will require a fixture.
The straightening can be carried out with the supplied straightening tool. Hammers of
hard rubber or wood may also be employed.
A suggestion for a straightening fixture is shown in fig. no. 6.
Side guides
As the straightening is carried out it might be beneficial to install the guide clip. The
clip is inserted in a slot on the edge of the plate.
Shipping crate
After straightening return the collecting plates to the shipping crate. It is important
that all handling is done with the body of the plate in a vertical position. This is to
prevent bending of the plates.
18/40
52221-06
Straightening fixture
POS.
POS.
POS.
POS.
POS.
1:
2:
3:
4:
5:
FIG. 6
Length of collecting plate minus 20 %.

1,5 mm wider than the edge of collecting plate.
15 mm wider than the edge of collecting plate.
20 mm higher than the collecting plate.
75 mm lower than the collecting plate.
19/40
52221-06
7.4
Erection of collecting plates, top rapping
See fig 7.
Methods
There are 2 ways to install the collecting plates.
Either one by one or row by row. It depends of filter size, lifting capacity, weather etc.
One by one
Supporting beams
Place the supporting beam in the guide angle and the guide iron, and align them
longitudinal. Check distances between the collecting plates perpendicular to the gas
direction. There should not be differences greater than 10 mm.
When they are aligned and vertical, weld them only to the guide angle, not to the
guide iron.
Rapping bars
Install all rapping bars on top of the supporting beams. The bars are guided
longitudinally at the front end by pins on both sides of the vertical guide plates.
The vertical guide plates together with the small guide plate in the rear of the
supporting beam control the bars transversely.
The mounting bolt in the rear of the rapping bar must be so loose, that the rapping bar
can move freely longitudinal.
Collecting plates
The collecting plates are lowered through the roof into the casing. They are guided in
between the suspension-beams. The plates are lowered below the suspension beam
and then lifted up in between the 2 members of the beam and rapping bar. With the
plate in the correct position, fasten it to the rapping bar with bolts. The bolts should
only be hand tighten at this step.
The collecting plates are installed row by row within a field. It is often more practical to
start from the side walls and work towards the centre of the field.
Important
It is of outmost importance that the individual collecting plates at this stage are
checked for bow and twist. Later it might be very impractical and difficult to do any
straightening.
Lower guide bar
For each group of rows of collecting plates, the group determined by the number of
guides in the lower spacer bar, install the lower guide bars.
20/40
52221-06
Erection of collecting plates
POS.
POS.
POS.
POS.
POS.
POS.
POS.
POS.
POS.
1:
2:
3:
4:
5:
6:
7:
8:
9:
FIG. 7
Hole in collecting plate for hooks.

Crane for erection.
Lifting tool for several collecting plates.
Collecting plates.
Box with collecting plates.
Rack for box with collecting plates.
Bracket for rack.
Hook for collecting plate.
Hole for pin to secure the collecting plates during erection.
21/40
52221-06
Row by row
Preassemble
Erect a row of collecting plates on the ground complete with supporting beam, rapping
bar and lower guide iron. The bolts are only hand tighten, so the collecting system can
be adjusted when all the rows are installed in the field.
Lifting jig
To avoid damage to the collecting plates, the rows have to be lifted in a jig. The jig
can be constructed, so it can hold several rows.
Control
Install all the rows in the guide angles and guide iron. When all the rows in a field are
installed, check the dimension cross field, there should not be differences greater than
10 mm.
Weld the supporting beams to the support angles.
Spacer bars
With all the collecting plates installed, mount all the spacer and guide bars transversely
in the field. The bolts shall only be tightened by hand.
Control
Check the straightness of all the rows of collecting plates. The checking is carried out
by lowering a plumb line from the supporting beam. Fasten the lower guide bars and
the spacer bars, when the lower guide bars are centred below the supporting beams,
and the collecting plates are vertical.
Centre guide
Use the centre guide for the final adjustment of the collecting plates sheets. Note that
the centre guide is only for minor adjustment.
Shrouds
The shrouds are installed on the rapping bars and the lower guide bars. Fasten the
shrouds to the rapping bars with the same bolts which suspend the collecting plates.
Tightening of bolts
The suspension bolts for collecting plates are tightened to the torque stated on the
drawing documentation.
7.5
Erection of collecting plates, bottom rapping
Preassemble
Erect a row of collecting plates on the ground complete with supporting beam, rapping
bar, shroud, and if any, the collecting plate clips. Weld the collecting plate Clevis pins
(bolts).
Lifting jig
To avoid damage to the collecting plates, the rows have to be lifted in a jig. The jig can
be constructed so it can hold several rows. The rapping bar must be secured against
deformation during lift. The securing must not be welding.
Control
Install all the rows in the guide angles and guide iron, at the top, and at the bottom.
When all the rows in a field are installed check distances between the collecting plates
perpendicular to the gas direction. There must not be differences greater than 10
mm.
22/40
52221-06
Weld the supporting beams to the roof beam in inlet end.
Check the straightness of all the rows of collecting plates. The checking is carried out
by lowering a plumb line from the supporting beam.
7.6
Installation of discharge frames
Uncrating and handling

During handling of the discharge electrodes it is important to exercise great care. The
emitters on the electrodes are delicate and may easily be bent during the transfer from
the shipping crate into the precipitator. Bend emitters have an adverse effect on the
precipitator performance.
7.7
Discharge system with vertical rapping:
Installation procedure
For the performance of the precipitator it is important that the individual discharge
frames have equal diagonal measurements. The frames must be without bow. After
welding of frame parts it may be necessary to straighten out the supporting electrodes.
Completely preassemble the discharge frames on the ground on an installation jig.
When all collecting plates are installed, the discharge frames can be lowered into the
filter. This can be done in one of the following ways:
1.
Lower the frames down between the collecting plates before mounting the main
beams on provisionally supports. Suspend them temporarily on the collecting
system.
2.
Or start by mounting the main beams on provisionally supports and lower the
discharge frames directly into place in the suspension brackets on the beams. This
method needs more caution in order not to damage the emitters on the supporting
electrodes.
Main beams
The two main beams must be supported on provisionally supports when the discharge
frames are suspended from the suspension brackets. See fig. no. 8.
Mount 2x2 provisionally support beams (e.g. I-beams) on the roof beams. Place the
support beams so the main beams will be supported at or close to the final
suspension points. Add tension members from the beams to the roof beam and
mount vertical supports to ensure the right position of the main beams.
Place the main beams in their right position on the supports. Fix by tack welding to
avoid movement or rotation of the beams. Make sure the beams are completely
vertical at the points where the supporting rods will later be placed.
23/40
52221-06
Installation of main beams
24/40
FIG. 8
52221-06
Check
Before installing the discharge frames it is important that the following points are
finished and checked:
The diagonal measurements must be within 5 mm.
The support electrodes and frame parts are correctly assembled and secured by
welding.
The emitters on the discharge electrodes are orientated correctly.
The discharge electrodes are correctly and finally fastened.
The bow must be within 5 mm.
This can be done in one of two ways:
1. Lower the preassembled discharge frames down between the collecting plates and
temporarily support them on the collecting system. Place rods in the holes in the
supporting electrodes or use special made hooks for the suspension. When all
frames are inside the filter install the main beams as previously described. Mount
the suspension brackets on the beams and lift each discharge frames into the
suspension brackets and install the suspension pins. Start from the centre of the
field.
2. Or start by mounting the main beams on the provisionally supports. Then lower
each discharge frame into the filter and suspend them directly in the suspension
brackets on the beams.
Using this method the work must be done with utmost caution in order not to
damage the emitters on the supporting electrodes. If necessary slightly increase
the distance between the main beams when installing the frames and move the
beams back to the correct position before alignment.
Provisionally alignment of discharge system
Both in the top and in the bottom, longitudinal and transverse, the frames should be
centred between the collecting plates at this point before joining the frames by
installing the lower guide irons and before suspending the discharge system by the
supporting rods.
NOTE
It may be necessary to heat up and slightly bend the discharge frames in order to
make a good longitudinal alignment in the bottom. (A thorough alignment at this point
will save time later)
7.8
Discharge system with horizontal rapping
Check
Before installing the discharge frames it is important that the following points are
finished and checked:
The
The
The
The
diagonal measurements must be within 5 mm.

emitters on the discharge electrodes are orientated correctly.
discharge electrodes are correctly and only fastened by hand
bow must be within 5 mm.
25/40
52221-06
Installation procedure
For the performance of the precipitator it is important that the individual discharge frames
have equal diagonal measurements. The electrodes must be without bow.
Completely preassemble the upper and lower discharge frames with electrodes on the
ground on an installation jig. The bolts for the electrodes must only be tightening by
hand. When all collecting plates are installed, the discharge frames can be lowered into
the precipitator.
Lower the frames down between the collecting plates before mounting the discharge
supporting beams. Suspend them temporarily on the collecting system.
Erection of supporting beams can be done in one of the following ways:
Preassembly the supporting beams on the ground with support for bearings, brackets
for bearings, hammer shaft hammers etc. Lift the supporting beams into the
precipitator and put them on a temporary support. Lift one discharge frame in place
between the supporting beams at a time.
Or place a supporting beam at each end of the discharge frames. When all frames are
in place, erect brackets for bearing to stiffen the top of the discharge system and
clamp for rapping to fixate the discharge frames. Lift the discharge system as a hole
in the right position.

This can be done in one of two ways:
1.
Lower the preassembled discharge frames down between the collecting plates and
temporarily support them on the collecting system. Place temporary support on top of
the rapping bars for the collecting system in a way so the upper discharge frame rest
on the angle iron. The temporary support must be a least 50 mm high. When all
frames are inside the filter install the supporting beams as previously described. Lift
each discharge frames into the supporting beams and secure the frames with the
clamp. Start from the centre of the field.
2.
Or start by mounting the supporting beams on the provisionally supports. Then

lower each discharge frame into the filter and place them directly in the supporting
beams. In order to get the discharge frames in place is it necessary to tip them
during the lift into the supporting beams. Using this method the work must be done
with utmost caution in order not to damage the emitters on the electrodes.
Provisionally alignment of discharge system

Both in the top and in the bottom, longitudinal and transverse, the frames should be
centred between the collecting plates at this point before joining the frames by installing
the lower guide irons and before suspending the discharge system by the supporting rods.
26/40
52221-06
7.9
Erection of rapping gears, top rapping
Collecting system
See fig. no. 9.
Bearing bridge
The rapping mechanism to be installed as a complete unit for each section of rapping
bars. The whole bearing bridge can be preassembled completely with horizontal shaft,
stop rings, big lantern wheel and hammers. The vertical shaft cannot be mounted until
the roof plates are positioned.
Installation is performed as follows:
Anvil unit
If the discharge system has horizontal rapping the anvil units for the collecting system
must be mounted on each individual rapping bar.
If the discharge system has vertical rapping the anvil units for the collecting system
must be mounted between two rapping bars.
Check that the impact points of the anvil units are aligned on a straight line transverse
of the section.
Location
Weld the flat bars between the supporting beams in accordance with ref.doc.
Install the brackets for the bearing bridge on the flat bars between the supporting
beams. Check that the measurements are in accordance with ref. doc.
Alignment
Check the entire shaft for straightness. Align the bearings rapper shaft longitudinally by
moving them in the elongated holes. In the height by shims.
Vertical and horizontal distance from centre line of shaft to impact point on anvil unit
must be in accordance with ref. doc.
Adjustments and control
Install all hammers in their approximate position.
Notice that one side of the hammer club has a protrusion which must face the anvil
unit at impact.
Turn the shafts to the point where a hammer is tumbling over.
With the hammer just tumbled over fix the shaft.
Check that the hammer makes an impact 2 mm above the centre on the anvil unit.
Also check that the impact occurs when the hammer is in vertical position.
During operation this position will ensure the centre of the hammer club makes
impact on the centre of the anvil unit. Also the position will ensure a reaction free
impact on the pivot point for the hammer club.
Final clamping
When the shaft is in its final position tighten all U-clamps.
Check the shaft position transversely. Adjust the clearance in the expansion
couplings in accordance with the ref. doc. Install the stop rings on both sides of one
bearing for each shaft section.
Erection tool
For the installation of the hammers make a protractor tool as shown on fig. 9. This will
make the installation of the hammers more practical. When a hammer is installed the
next hammer must have an offset of 150 degrees. Install the hammers as follows:
27/40
52221-06
Turn the shaft to the point where a hammer falls.
Check the position of the hammer as it impacts on the anvil unit.
Tighten the nuts on the U-clamps. Ensure the U-clamps are making complete
contact against the shaft and the nuts are tightening evenly.
Fix the protractor to the shaft with a hammer in fall position and the pointer on a
mark.
Then turn the shaft to the next 150 degree mark.
Adjust the corresponding hammers and tighten the nuts on the U-clamps.
Securing of hammers
With all hammers installed weld the stop block to the shaft as shown on ref. doc. The
stop block prevents axial movement if any hammer should become loose.
Secure all nuts on the hammers and bearings as shown on ref. doc.
28/40
52221-06
Erection of hammers top rapping, discharge system with vertical

rapping
FIG. 9
POS.
POS.
POS.
POS.
POS.
POS.
1
2
3
4
5
6
:
:
:
:
:
:
Collecting system.
Discharge system.
Erection tool, degree disc.
Rapping shaft.
Chip.
Fall position.
29/40
52221-06
Discharge system with horizontal rapping
Fig 9a
Lantern wheel
The lantern wheels on the horizontal shaft are mounted, but not weld, on the shaft
during preassembling on the ground.
After the roof plates have been mounted, the vertical shaft and roof drive is
positioned. Engage the 2 lantern wheels in accordance with ref. doc.
The lantern wheel installed on the rapper shaft has a hole. This hole will make
clearance for the pivot bolt on the hammer if the hammer is too close to the wheel.
With correct engagement of the wheels weld the stop rings at the lower bearing for
the vertical shaft. Weld the wheel on the rapper shaft to the shaft.
Final control
Final control and possible adjustments of the hammer impact points is best done by
rotating the shaft.
The rotation will make impact marks on the anvil units.
Erection of rapping gears, bottom rapping
After all the collecting plates are installed, the bearing bridge can be welded to the
gangway.
Check the entire shaft for straightness. Align the bearings longitudinally by moving
them in the elongated holes. In the height by shims. Vertical and horizontal distance
from centre line of shaft to impact point on rapping bar, must be in accordance with
ref. doc. After alignment of the rapping bars, secure the bolts for the guide angles
by welding.
30/40
52221-06
Adjustments and control
Install all hammers in their approximate position.
Notice that one side of the hammer club has a protrusion which must face the anvil
unit at impact.
Turn the shafts to the point where a hammer is tumbling over.
With the hammer just tumbled over fix the shaft.
Check that the hammer makes an impact 2 mm above the centre on the anvil unit.
Also check that the impact occurs when the hammer is in vertical position.
During operation this position will ensure the centre of the hammer club makes
impact on the centre of the anvil unit. Also the position will ensure a reaction free
impact on the pivot point for the hammer club.
Discharge system vertical rapping:
See fig. no. 9
After the main beams for the discharge system has been provisional placed, mount
the horizontal shaft with hammers and lantern wheel.
Notice that if there is a protrusion on one side of the hammer club, it must not face
the anvil unit at impact.
Alignment of rapper shaft
Alignment, adjustment and installation of rapper shaft and hammers is carried out
as for the shaft for the collecting system. Except for a few points:
The flat side of the hammer club is the impact side.
The impact marks on the frame part and the hammer club must coincide. The
checking and adjustment is carried out by moving the hammer by hand from its
tumbling position.
Final control
Final control and possible adjustments of the hammer impact points is best done
by rotating the shaft. The rotation will make impact marks on the anvil units.
Discharge system horizontal rapping:
See fig. no. 9a
After the supporting beams for the discharge system has been provisional placed,
mount the horizontal shaft with hammers and lantern wheel, if not already done.
Notice that the protrusion on one side of the hammer club, must face the anvil unit
at impact.
Alignment of rapper shaft
Alignment, adjustment and installation of rapper shaft and hammers are carried out
as for the shaft for the collecting system.
Final control
Final control and possible adjustments of the hammer impact points is best done
by rotating the shaft. The rotation will make impact marks on the anvil units.
31/40
52221-06
7.9
Installation of lower support flange for discharge system

See fig. no. 10.
Install the roof plates which support the insulators.

When the plates are aligned weld the plates to the casing.
Location
In accordance with the drawing documentation place the lower insulator support
flange in their approximate position.
Erection tool
For location of the centre for the lower support flange, fabricate 4 or 8 tools as
shown on fig. no. 10. Place the tools on the support flanges within one field.
Installation
Place the lower support flanges within the field after the following guide lines:
Based on the centre line of the precipitator casing, establish a centre line for
each line of cells.
Stretch 2 strings tight (piano wire or nylon) over the centres of the support
flanges parallel to the centre line. The dimensions from the casing line and
between the flange centre lines must be in accordance with the ref. doc.
For stretching the strings weld braces on the installed roof plates.
Place the 2 first support flanges with their centres directly below the strings.
Move the centre of the flanges to comply with the distance from the roof beam
in accordance with ref. doc.
Place the other flanges so their centres are under the strings. The distance
between their centres must be in accordance with ref. doc.
Control
Measure the diagonals. They must be of equal distance and within 5 mm.
Check also that the centres with respect to the already installed collecting plates
are within 5 mm.
32/40
52221-06
Placing of support flanges for discharge system
POS.
POS.
POS.
POS.
POS.
POS.
POS.
POS.
POS.
POS.
1:
2:
3:
4:
5:
6:
7:
8:
9:
10:
FIG. 10
Tool for erection of supporting flanges.

Inner diameter at supporting flanges minus 1 mm.
Supporting flange without guard tube.
Supporting flange with guard tube.
Centre hole a 2 mm.
Checked centre line at roof beam.
Collecting system.
Discharge system.
Measurement according to erection drawing.
Diagonals.
33/40
52221-06
7.10 Erection of discharge system
Install the support insulators and the suspension rods in accordance with ref. doc. Then
install the guard tubes centred around the rod.
Adjustment and control
With the main beams, or supporting beams, and the discharge frames mentioned
above installed, adjust and check the correct position of the discharge system.
Adjust and check the main beams or supporting beams, and discharge frames
correct height position in accordance to ref. doc.
The adjustment is carried out by moving the suspension rods up or down. This is
accomplished by turning the suspension nut.
Adjust and check the installed discharge frames between the collecting plates. They
must be centred in accordance with ref. doc. The adjustment is carried out by
moving the lower support flange, the support insulators and/or suspension rods.
Discharge system vertical rapping:
Final installation of discharge system
When the discharge frames are in correct position, secure the discharge frames guides
(and locking pieces) for the support electrodes by welding.
Check successively that each frame is centred between the collecting plates.
Lower guides
With all the discharge frames finally adjusted and checked longitudinally install the
lower guide irons.
Tighten the u-bolts stepwise to the prescribed torque, see ref. doc. Weld the u-bolts
according to drawing. If the welds are too long the heat may spoil the alignment.
The purpose of the guide irons is to control and fix the discharge frames in the correct
transversely and longitudinally position.
Alignment
With all guide irons installed on the front and back of the discharge frames check the
transverse and longitudinal position of the assembled discharge system.
Discharge system horizontal rapping:
Final installation of discharge system
Check successively that each frame is centred between the collecting plates.
Lower guides
With all the discharge frames finally adjusted and checked longitudinally install the
lower guide irons.
Tighten the bolts to the prescribed torque, see ref. doc. according to drawing.
The purpose of the guide irons is to control and fix the discharge frames in the correct
transversely and longitudinally position.
Alignment
With all guide irons installed on the front and back of the discharge frames check the
transverse and longitudinal position of the assembled discharge system.
Tack weld the lower discharge frame to the guide irons, and tighten and tack weld bolts
for the electrodes.
34/40
52221-06
Discharge system, horizontal and vertical rapping:
Final control
With the discharge system freely suspended check all "voltage gaps" with a gauge. The
system must be checked at the top, centre and bottom.
Adjustments at the top can be carried out as previous described in this chapter.
Transverse adjustments at the bottom can be carried out by help of the butt
straps which have elongated holes. After adjustment, weld the butt straps.
Important
The performance of the precipitator is greatly influenced by the spacing between
discharge electrodes and collecting plates. Consequently it is important that the
spacing is within the tolerance.
Securing of the field
When the electrode system is correctly installed it might be advantageous to temporary
fix it to the side walls. This will prevent any movement of the installed system while
the following system is being installed.
7.11 Cutting loose, final control of spacing and securing of bolts
See fig. no. 11.
Cutting loose
In the case the discharge system has been temporarily fixed to the side walls cut it
loose. It must be loose for the final spacing control.
Control
Check that the individual discharge frames have not shifted during the erection. The
check is carried out over the entire cross section.
Securing of bolts
When the discharge system is in the correct position secure all bolts and nuts in
accordance with the ref. doc. Any possible outstanding welding must be finished.
7.12 Final
Submittal of control form
To guarantee that the result of the erection regarding the internal systems is correct
and comply with the tolerances, fill in the control forms. The control forms for
mechanical installation must be submitted to the head office.
The filled in control forms will always be commented on by the head office. The
erection will not be considered finish before an acceptance of the submitted forms is
received.
35/40
52221-06
Control of voltage-gab
a, b:
POS. 1:
POS. 2:
POS. 3:
36/40
Measurement according to drawing.

Rapping bar, upper.
Guide bar, lower.
Measuring toll.
FIG. 11
52221-06
8 Roof plates
Erection
The rest of the roof can only be erected after the internals are placed in the filter casing.
9 Inspection doors and hatches

Cut out
Inspection doors and hatches must be joined to the plates with gas-tight welds.
Erection
With regard to positioning the insulation door on the inspection door, make sure there is
room for the insulation in and around the door.
Control
Check that the sealing surfaces of the frames are straight after welding.
Drivers for rapping
Do not make the cut outs for the drives until after the rapping shafts have been erected.
10 Completion of filter casing erection

Control of gas-tightness
The gas-tight welding must be done carefully and control must be thorough, as even small
leaks can cause serious corrosion damage.
Measurement
Check the finished, welded filter casing; plot corrected centre control forms marks and
complete control form.
11 Preparation of precipitator for operation

Before the precipitator is put into operation the following preparations must be carried
out:
Lubrication
Bearings
The internal bearings for the electrode systems must not lubricated
Test run
Rapping mechanisms
The following must be checked in connection with the test run:
-
The rotation of the geared motors before assembling of the roller chain
All the hammers rotate freely
The dielectric shafts have free axial play
Start rapper drives and "cold" run for 24 hours
After run check that nothing has shifted
37/40
52221-06
Preparation for operation
Access
Check that all walk ways and inspection areas are installed and secured in accordance with the
regulations.
Cleaning
Remove all welding rods, all tools, scaffolding, plumb and centre line strings, all erection clips
etc. from the interior of the precipitator. Clean all insulators and their compartments.
Safety
Check that the safety regulation for work on the precipitator is available at the plant.
Check that the precipitator complies with the respective documentation and the local safety
regulations.
Start up of precipitator
Test run and start up must be carried out in accordance with the respective operation instruction.
38/40
52221-06
12 Legend for principle drawing

See fig. 12.
01
02
03
04
05
Rapping device for collecting system

Drive shaft for collecting rapping device
Supporting insulator
Insulated drive shaft for discharge rapping device
Rapping device for discharge system
06
07
08
09
10
Main beam for discharge system

Casing
Collecting plate
Gas distribution screen in outlet
Outlet
11
12
13
14
15
Guide iron for discharge system

Guide bar for collecting system
Guide lower for collecting system
Inlet
Gas distribution screen in inlet
16
17
18
Frame part for discharge system

Supporting beam
Rapping bar
39/40
52221-06
Principle drawing
FIG. 12
---o0o---
40/40

Esp e

Uploaded by

Document Information

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

Esp e

Uploaded by

Copyright:

Available Formats

.

Erection of filter casing and internal systems

Welding regulations ...................................................................................... 4

Preparations work ......................................................................................... 4

Erection of filter casing .................................................................................. 6

Erection of internal systems .......................................................................... 16

Inspection doors and hatches ......................................................................... 37

10 Completion of filter casing erection ................................................................. 37

Manual for control forms

Drawings and parts lists

Dimension and load drawing

electrostatic precipitator is designed to clean flue gasses from

power station boilers

cement kilns and raw mills

electric charging of the dust particles, collecting and then

mechanical shaking with rapping device

removal with mechanical transport equipment

Control and use

Receiving and handling of equipment

Storing and uncrating

inlet and outlet

5 Erection of filter casing

See erection manual for steel support/roller bearings/journal bearings.

Assembly and welding of portals

Erection of first portals

Erection of filter casing

Assembly and welding of portals on the ground.

Erection of filter casing

Erection of filter casing

Erection of inlet and outlet.

Portals with centre column

Erection of other portals

Pull gable walls together, approx. 150 mm. Fig. 4.3.

Assembly and welding of pyramid hopper on the ground.

Welding of filter casing

See "General Workshop Instructions".

Fully weld the sealing plates at the bottom beams.

Ultimately, the filter casing must be gas-tigh throughout.

6 Inlet and outlet

7 Erection of internal systems

Control and establishing of centre line

Transversely and longitudinally the casing must be square.

Erection of guide angle and guide iron

Erection of supporting beams for collecting plates

Roof beam, end wall.

Before erection of collecting plates

Length of collecting plate minus 20 %.

Erection of collecting plates, top rapping

Erection of collecting plates

Hole in collecting plate for hooks.

Erection of collecting plates, bottom rapping

Installation of discharge frames

Uncrating and handling

Discharge system with vertical rapping:

Installation of main beams

Discharge system with horizontal rapping

diagonal measurements must be within 5 mm.

Installation of discharge frames

Or start by mounting the supporting beams on the provisionally supports. Then

Provisionally alignment of discharge system

Erection of rapping gears, top rapping

Erection of hammers top rapping, discharge system with vertical

Discharge system with horizontal rapping