ESP Manual
ESP Manual
ESP Manual
6.1.1 Introduction
6.1.2 Principle
6.1.3 Working
6.1.4 Advantages of ESP
6.1.5 Parameters affecting ESP performance
6.1.5.1 Resistivity of Dust particles
6.1.5.2 Flue gas temperature at ESP inlet
6.1.5.3 Flue gas volume flow rate through ESP
6.1.5.4 Flue gas composition
6.1.5.5 Percentage of Moisture in flue gas
6.1.5.6 Percentage of sulphur oxides in flue gas
6.1.5.7 Percentage of oxides of salts in flue gas
6.1.5.8 Percentage of Alkali metals in flue gas
6.1.5.9 Flue gas velocity within ESP
6.1.5.10 Inlet dust concentration
6.1.5.11 Outlet dust concentration
6.1.5.12 Gas distribution inside ESP
6.1.5.13 Rapping Frequency
6.2.1 Introduction
6.2.2 Collecting Electrodes
6.2.3 Emitting Electrodes
6.2.4 Slide Bearings
6.2.5 TR set with Controller
6.2.6 High Voltage Support Insulators
6.2.7 Mechanical Safety Interlock System
6.2.8 Hopper Heaters
6.2.9 High level Switches in Hopper
6.2.10 ESP casing, Hoppers ,inlet & outlet Funnels
6.2.11 Collecting Electrode Suspension
O & M MANUAL FOR ESP
6.2.12 Collecting Electrode Rapping
6.2.13 Emitting Electrode Suspension
6.2.14 Emitting Electrode Rapping
6.2.15 Gas Distribution Screen Arrangement
6.2.16 Electrical Hoist
6.2.17 Insulation and Cladding Mattress
6.3.1 Introduction
6.3.2 Mechanical key interlock system
6.3.3 Discharge rod
6.3.4 Dos & Don'ts
6.3.5 Fire Explosion
6.4 COMMISSIONING
6.5 MAINTENANCE
6.5.1 Introduction
6.5.2 Maintenance of gas distribution
6.5.3 Maintenance of voltage distance
6.5.4 Maintenance of dust deposits
6.5.5 Importance of Ash Evacuation from hoppers
6.5.5.1 Phenomena of Ash Collection
6.5.5.2 Importance of Ash Evacuation
6.5.6 Maintenance check list
6.6.1 Introduction
CONTENT
SL.NO. ITEMS UNITS VALUES
Total Collecting Area m2 54432
Number of Electrodes Per Stream Nos 1386
Total Number of Electrodes Nos 2772
Aspect Ratio (L/H) 2.33
D Discharge Electrodes
Type Spiral
Material SS UHB 904 L
Distance Between Effective Discharge
mm 150/225/225/150
Electrode In Direction of Gas Passage
Total Number of Electrodes Nos 24550
Electrode Wire Diameter mm 2.7
Spacing of Electrode Across the Flow mm 400
Tensioning Arrangement Self Tensioned
E Bus Section
Number of Bus Sections across the flow Nos One
HT Voltage Kv 95
Number of Sections Lost If one
Nos One
Transformer is out of Service
Rapping System – Collecting
F
Electrode
Type Tumbling Hammers
CONTENT
SL.NO. ITEMS UNITS VALUES
Input Rapping Power to Rapping System KW 0.37
H Rapping System – Emitting Electrode
Type Tumbling Hammer
No. of rapping system/ESP Nos 7
Total no. of rapping hammers/rapping
Nos 34
system
Time Interval Between Raps of same
s Field Adjustable
Rapper
Input Rapping Power to Rapping System KW 0.50
I Rapper Controller
Type Micro controller Based
Timing Sequence Programmable
Protection IP 54
Indicating Instruments LED
J High Tension Support Insulator
Type Cylindrical
High Alumina Porcelain
Material
CONTENT
SL.NO. ITEMS UNITS VALUES
N Transformer
Step UP Double
Type of Transformer
Wound
Rating of Each Set
Input Power KVA 122.25
Output Power KW 97.80
Output Voltage (Peak) KV 95
Output Current (Mean) mA 1400
Volume of Oil Litres 700
O Rectifiers
Type SCR Bridge
Hall-Wave / Full-Wave Full – Wave
P TR Set Control Panel
Number Offered/ESP 7
Type of Cabinet Free Standing
Control Constant current
Arc Suppression Provided
Protection IP 55
Instrumentation Provided as required
As per supplier
Signal Circuit
Standard
Design ambient Temperature Deg C 50
415 V, 1 Phase,
Power Supply V, Phase, Hz
50 Hz
Earthing And Shielding Provided
Q ESP Casing
Plate Thickness mm 6
Design Pressure mmWg +/- 660
Design Temperature Deg C 200
Construction Welded Type
Material IS 2062
R Fly Ash Hopper
Total Number/ESP 14
Total Hopper Storage Capacity/Field m3 108.55
Plate Thickness mm 6
CONTENT
SL.NO. ITEMS UNITS VALUES
Material IS 2062
Hopper Valley Angle Deg 60
S Fly Ash Hopper Electrical Heaters
Rating KW 0.5
Number Per Hopper Nos 12
Control Thermostat
T Gas Screens
Perforated Formed
Type
Sheet
Material IS 1079
Thickness mm 2
CONTENT
6.1 WORKING PRINCIPLE
6.1.1 INTRODUCTION: -
The suspended particulate matter from the industrial exhaust is the major
pollutant of the atmosphere. The exhaust flue gas consists of solid as well as
fluid suspended particles. In most of the industrial processes these suspended
particles are the residues of those processes and they have to be removed before
they are let into the atmosphere. In some industrial processes, these suspended
particles may be useful or reusable products to be collected to make the process
more profitable. An earlier stage ESP had been used for this purpose only. Later
on it has been found as a way of most efficient dust collecting equipment for
many of the industrial applications.
6.1.2 PRINCIPLE: -
6.1.3 WORKING: -
In the electrostatic precipitator, the dust laden flue gas is passed through
the passages between the collecting and emitting electrodes. The emitting
electrode is a self-tensioned spring mounted in a framework and collecting
electrode is of curtain like plate hung from top. A Transformer rectifier set will
feed a very high DC voltage to the emitting electrodes (negative polarity) whereas
the collecting plates are earthed (positive polarity). This high voltage emitting
system ionizes the flue gas stream and form positive, negative ion cloud inside
the electrostatic precipitator.
Once this cloud of charge is produced it will start charging the dust particle
to its saturation level. The (negatively charged) dust particles will be attracted
towards the (positively charged) earthed collecting electrode plates and get
deposited. The movement of dust particles towards collecting electrodes will be
O & M MANUAL FOR ESP
CONTENT
opposed by viscous drag, collision of dust particles etc., and the resultant velocity
with which the particle moves towards the electrode is known as migration
velocity or drift velocity.
As soon as the dust particles get precipitated over the collecting electrode
panels, they get discharged as the panels are earthed. The collected dust will be
removed by the rapping mechanism at suitable preset timings.
Electrostatic Precipitators are usually designed for a set of inlet flue gas
conditions. Variations in one or many of these parameters may lead to alteration in
collection efficiency in Electrostatic Precipitator.
CONTENT
Parameters influencing the performance of Electrostatic Precipitator are
• Resistivity of dust particles
• Flue gas temperature at ESP inlet
• Flue gas volume flow rate through ESP
• Flue gas composition
• Flue gas velocity with in ESP
• Inlet dust concentration
• Dust particle size distribution
• Gas distribution inside ESP
• Rapping frequency
The problem due to high resistive dust particles is the back corona
formation. Usually while operation there will be a voltage drop across the dust
layer collected over the collecting plates. If the resistivity of dust layer is very
high, this voltage drop will increase and it may be sufficient to produce sparking
between collecting and emitting electrodes. In order to avoid this back corona
effect, the operating voltage and current of the precipitator can be reduced.
CONTENT
back corona effected thereby bringing down the operating voltage to reduce
sparking. This plays a vital role in reducing the ESP performance at elevated
temperatures. The above two phenomenon will significantly reduce the effective
migration of dust particles thereby affecting the overall performance of the
precipitator. This is the reason why an ESP designed for a specific flue gas
temperature may not perform satisfactorily at higher temperatures.
The lower operating temperature will aid the performance of ESP as the
resistivity of dust particles reduce with decreasing temperature. The lower
operating temperature will create problem if it falls below the acid dew point
temperature leading to corrosion of structural and mechanical components of
ESP.
Based on the flue gas composition the amount of collection area required
for conditioning the gas to the required dust level will vary. The amount of
collection area required per cubic meter of flue gas is called as the specific
collecting area (SCA). The total collection area (TCA) of the precipitator will be
arrived by multiplying the SCA with the design flue gas flow rate. Increase in gas
volume will therefore decrease the SCA required for the flue gas and thus
reducing the performance of electrostatic precipitator.
The composition of flue gas plays a vital role in design as well as in the
performance of ESP. The effect of some of the major composition of flue gas,
which highly affects the performance of ESP, has been briefed below
The percentage of water vapour present in flue gas has a greater influence
on the performance of ESP. The more percentage of water vapour will aid the
performance of ESP by reducing the resistive nature of flue gas. If the ESP has
been designed for a specific percentage of moisture in flue gas, then the
performance of the ESP will deteriorate with decreasing moisture percentage. A
CONTENT
maximum increase of 5% of moisture in flue gas can improve the performance of
ESP to certain limit.
The free sulphur trioxide formed during the combustion of fuels condenses
with moisture on the surface of the particles and thus reduces the resistivity of
dust particles. In some cases larger portion of sulphur in fuel may form as calcium
sulphate, which is highly resistive despite of high sulphur content.
The formation of sulphur trioxide may raise the sulphur dew point
temperature thereby wetting the dust by the sulphuric acid formed. This makes
the dust to get clogged into ESP and reducing the performance of ESP.
The presence of oxides of salts like calcium and magnesium oxides will
result in formation of dust layer over emitting electrodes and thereby suppressing
the corona formation. This reduces the performance of ESP.
The alkali metals like sodium and potassium present in the fuel forms alkali
sulphates, which increases the moisture absorbing capacity of dust particles.
Hence the collection rate will increase if the alkali metals are present in larger
amount.
The flue gas should flow as a streamlined flow inside the ESP with an
optimal velocity. Higher operating velocity will decrease the effective migration
velocity as well as the carryover of collected dust particles along with flue gas.
Lower operating velocity will lead to stagnation of flue gas at lower zones of ESP.
The SCA provided is suitable for a particular amount of inlet dust load to
achieve the required outlet emission. Hence if there is any drastic increase in the
amount of inlet dust concentration the collection area provided will not be
adequate to achieve the required outlet emission.
CONTENT
6.1.5.11 OUTLET DUST CONCENTRATION: -
The flue gas entering into the precipitator should be evenly distributed over
the entire cross sectional area to achieve maximum performance. It avoids the
over loading of certain zones and non-usage of certain electrode zones.
Practically it is not possible to attain perfect distribution of flue gas over the entire
area especially at the lower and upper extremities of electrodes. The variation of
flue gas in this areas has to be minimized and maintained within a permissible
limit to achieve better performance.
CONTENT
6.2 COMPONENT DESCRIPTION
6.2.1 INTRODUCTION: -
As mentioned earlier the precipitator is made out of several bought out and
shop made items. The major bought out items involved are the electrodes both
collecting and emitting, insulators and transformer rectifier sets.
CONTENT
6.2.4 SLIDE BEARINGS:-
The ESP casing is supported over high efficient sliding bearings, which are
taking care of casing thermal expansions. Three types of bearings are normally
used called fixed, mono-axial and bi-axial bearings. The bearings have been
designed for various loads such as wind and seismic in addition to dead loads.
The bearing top plates to be bolted with casing column base plate and the
bearing bottom plate to be welded or placed in races provided in supporting
structure bearing plate.
As the dust laden flue gas passes through the collecting and emitting
electrodes, the ESP can be considered as a capacitance load having variable
dielectric strength. The dielectric strength varies due to changing parameters of
the flue gases.
The high voltage DC applied to the ESP has been continuously adjusted to
minimize sparking across the discharge and collecting electrodes. The voltage
controller in the transformer rectifier control cabinet senses the current feedback
from the ESP and does the following functions.
• It maintains the voltage across the ESP at the spark threshold level in all
the conditions to achieve optimum efficiency.
• In case of spark, it brings down the voltage by preset value. The voltage is
raised to spark threshold level if no further sparking is considered.
• In case of arc, it brings down the voltage to zero and blocks it for preset
time. The voltage is restored to the preset value by fast ramp and then to
the spark threshold level by slow ramp.
6.2.6 HIGH VOLTAGE SUPPORT INSULATORS:-
The entire emitting system is rested over high voltage porcelain cylindrical
insulator that isolates the entire system from the casing, which is earthed. The
support insulators have been designed for heavy compression loads. The
CONTENT
insulators are located over ESP hot roof inside separate heated
compartments. Each insulator is provided with a coil type of heater to maintain
the temperature of insulator slightly higher than ash condensation temperature.
One number thermostat is provided per field to control the insulator heaters at
required temperature level.
This system provides the safety of person attending ESP. This system
ensures that no person can enter into ESP unless all the Transformer Rectifier
sets are de-energized and grounding switches of TR sets are in ground position.
Continuous removal of collected ash from ESP ash hopper is essential for
better as well as safe working of ESP. In order to maintain the free flow of ash
through hopper discharge flange, the bottom portion of ash hoppers are heated
using coil type of heaters. This prevents ash build up in the hoppers. The
heaters are thermostatically controlled to maintain the temperature upto a
maximum of 230ºC.
RF type capacitance level switches are provided in each hopper. The level
switch operates when ash level inside the hopper rises and touches the level
switch probe. The level switch gives signal to the audio visual alarm annunciator
provided in the Auxiliary control panel to indicate high ash level in the hopper and
trips the TR set. Even after tripping the TR set, the dust will continue to buildup in
the hopper. Auxiliary contact of high hopper level relay will be provided in the
Auxiliary control panel. If the high level alarm is persisting, it is recommended to
stop the boiler after one-hour time delay. This prevents ash building up in the
hoppers, which ultimately shorts the emitting electrodes.
CONTENT
tolerances. The casing is being erected with higher care, which minimizes
electrode alignment problems and leakages.
Pyramidal type of ash hopper is provided for each field with sufficient
storage capacity and valley angles as per CVL standard design or to conform the
customer requirement. The inlet and outlet funnels are designed for proper
distribution of flue gas over the entire area of collecting electrodes across the
cross section of the precipitator.
The collecting electrodes are hung from hooks welded to support angles,
which in turn supported to ESP roof beam. The bottom of collecting electrodes is
bolted to shock bars, which makes the collecting electrodes into a single curtain.
The top and bottom suspension of collecting electrode curtains are suitably
locked by support angles and shock bar guides to avoid swinging or
misalignment. This firm fixing at top and bottom provides sufficient rigidity and
also uniform distribution of rapping force to the entire surface of the collecting
electrode curtain.
High efficient tumbling hammer type of rapping has been provided for both
collecting as well as discharge electrodes. Individual rapping hammer for each
row of collecting electrode panel is provided. The rapping force is transferred to
electrode through the shock bar pads. The rapping creates acceleration such
that the dust cake dislodges from the collecting electrode panels without getting
broken. This avoids the re-entrainment of collected dust into the flue gas stream.
The rapping frequency should be kept as low as possible, which provides
sufficient cleaning as well as to reduce the re-entrainment of collected dust.
Microcontroller based rapping programmer is provided to control each rapping
drive individually. The rapping programmer should be programmed in such a way
that minimum percentage of collecting electrode area should be rapped at any
one time.
The spiral electrodes are stretched between the top, intermediate and
bottom frames thus forming a complete framework. The spirals are kept self-
tensioned which reduces the swinging of electrodes. The taut wires are also
susceptible to rapping forces and hence stay clean always.
CONTENT
6.2.14 EMITTING ELECTRODE RAPPING:-
The gas velocity inside ESP will be much less than the velocity of flue gas
inside ducting before the precipitator. In order to achieve even distribution of flue
gas throughout the entire cross section of ESP, specially designed gas
distribution screens are located at the inlet of the precipitator. In addition to this,
deflector plates are also used to achieve better flow pattern. Clogging of dust on
screen plates may disturb the flow pattern and hence GD screens are provided
with rapping mechanism with tumbling hammers.
Electrical Hoist is used for handling ESP TR sets having capacity of 3 ton,
33 meters height and traveling beam size of ISMB 250 meters.
TECHNICAL FEATURES:-
CONTENT
6.2.17 INSULATION AND CLADDING MATTRESS :
The insulation material shall not have any tendency to plastic deformation
even under extreme operating condition of mechanical forces vibrations etc. The
Insulation and cladding shall be provided with surface temperature more than 50
deg .C. The insulation material is LRB mattress of 50 mm thick and 100 kg/m3
density .the cladding material is plain aluminium cladding sheet with a thickness
of 1 mm.
CONTENT
6.3 SAFETY PRECAUTIONS
6.3.1 INTRODUCTION:-
Each key is trapped in door lock when the door is open and can be
released only if the door is closed and locked. The control key for operating the
TR set panel will be released only if all the individual door keys are locked in key
exchange boxes. Thus the rectifier panel can be switched 'ON' only when all
access doors are locked and the grounding switch is in live position.
CONTENT
2. The grounding switches are to be put in grounded position.
3. The main fuse for the entire transformer must be in off condition.
DON’Ts
1. Volatile gases and / or heavy carbon particles will enter the precipitator if
there is any malfunctioning in boiler. The sparks in the precipitator could
ignite these carry over unburnts, causing fire or explosion thereby
damaging precipitator internals. To avoid such a fire hazard the transformer-
rectifier sets are immediately switched off thereby eliminating the possibility of
sparks inside the precipitator.
2. The dust layer on collecting plates and the collected dust in ash hoppers will
be at higher temperature and have high carbon content. Sudden opening of
access door will lead to spontaneous combustion of the hot dust due to
inrush of air inside the casing. Hence do not open the access doors until the
precipitator has cooled to near ambient temperature.
CONTENT
6.4 COMMISSIONING
The test is conducted by establishing cold air flow by operating the FD Fans,
ID Fans and PA Fans (wherever applicable). The velocity profile is studied inside
the precipitator chamber. The uniform distribution of flow is obtained by placing the
deflection plates and throttling plates, on the primary and secondary screens. This
velocity data are subjected to statistical analysis to find the deviation of each data
from the average. The test is repeated by adjusting the plate positions till the
velocity pattern is uniform and within acceptable limits across the ESP cross
section.
Digital or Analog Vane Type Anemometer shall be used for measuring the
velocity. The readings taken during the test are only relative measurement and the
calibration of the anemometer is not required.
The measurement points shall be distinctly marked on the trailing edge of the
collecting electrodes of the first field. The vertical spacing between the points is
approximately equal to 1/10 th of the nominal height of Collecting Electrode leaving
sufficient gap at the top and bottom of the collecting electrode.
CONTENT
The speed of FANs and Damper/Gate opening are adjusted such that the
average velocity in side the chamber is more than 0.5m/sec and closure to 1m/Sec.
The velocity reading shall be taken on every alternate Collecting Electrode.
The velocity profile shall be studied and flow shall be corrected by fixing
deflecting plates. The flow correction shall be accomplished using the following
methods.
• Plates are fixed both in the primary & secondary screens depending upon the
requirement.
CONTENT
13. Check all the insulator compartments and high voltage bus duct connection
are closed and locked in accordance with safety interlock system.
14. Charge the precipitator fields and try to reach the rated values of TR sets. If
the instrument shows zero value for voltage, it means that the system is in
short circuit. Clear the cause for short-circuiting and recharge the precipitator
fields.
1. Switch 'ON' all the insulator heaters. For cold start up the charging of precipitator
is done only after 12-18 hours from the time of switching on of heaters.
2. Start all rapping motors and run continuously in manual mode for 10 minutes and
put the system in auto mode.
3. Start the ash handling system and ensure it for proper working.
4. Switch 'ON' the control panel and start charging the ESP.
5. The rapping system for all electrodes and all the heaters for insulators as well as
for hoppers must be working during the operation of boiler and preferably
12-18 hours before start up to avoid the soot formation on electrodes.
6. The flue gas temperature at precipitator inlet should be always maintained above
120 deg centigrade. The precipitator should not be charged below 120 deg
centigrade to avoid clogging of dust on electrodes and to avoid corrosion due to
sulphur formation (acid dew points corrosion).
1. If the precipitator has to be stopped not due to the problem in precipitator, only the
TR set is to be put off.
2. If the precipitator has to be stopped due to the problem in precipitator, the TR sets
has to be put off followed by all the rapping motors operating under manual mode
for 4 – 5 minutes before opening the inspection doors. This is useful for a good
cleaning of emitting and collecting systems. This will also reduce the clogging and
corrosion dangers.
3. If the precipitator has to be stopped for normal shutdown, the TR sets are to be
put off. The rapping and heating systems must be kept in operation for at least 12
hours in order to ensure the cleaning of the emitting and collecting system. The
hopper evacuation system should also be kept on for complete removal of dust
from the hopper.
CONTENT
6.4.5 FINE TUNING: -
After initial commissioning of the precipitator on dust load, fine adjustment will be
necessary to optimize the performance of the precipitator. The tuning operation is
normally done after the plant has been stabilized at its full load without interruption
and able to maintain the specified system parameters at precipitator inlet. The
trimming involves the setting of right extent of power input to the precipitator and
optimal rapping frequency through rapping programmer.
NOTE:-
1. This test can be made with the heating system off, provided the insulators are dry
and that the test last for a short time.
2. If the heating system is on, the field should not be charged before 8 hours from the
heaters on time. This eliminates the humidity inside the insulators. The presence
of humidity on the insulators will cause electrical discharge on the insulators with
possible breakage of insulator if charged.
CONTENT
6.5 MAINTENANCE
6.5.1 INTRODUCTION:-
The life span and the performance of the precipitator depend on the
efficient maintenance of its system. A well-maintained precipitator will have
longer life with consistent good performance.
• Gas distribution
• Voltage distance
• Dust deposits
• Periodic Ash Evacuation of hoppers
CONTENT
6.5.5 IMPORTANCE OF ASH EVACUATION FROM HOPPERS:-
The total ash from the boiler enters into the precipitator along the flue gas.
The dust density in the flue gas depends on the quantum of the ash available in
the flue and the volume flow rate. The suspended particulate matter of dust
entering into ESP is heterogenous in nature and contains agglomeration of
coarser and finer particles.
The particulate matter engrained in flue gas is getting diffused as it enters into
the precipitator from a high velocity dusty duct to the precipitator chamber.
Normally the velocity within the precipitator will be below 1 m/sec. The dust
engrained in the flue gas passes through the collecting and emitting systems.
These systems are kept at very high voltage level and the corona discharge
occurs due to high voltage. The suspended particulate matter gets ionized,
charged and attracted towards the opposite polarity. Thus the suspended
particulate matter is collected at the collecting plate,as negatively charged particles
are predominant and they form the huge quantum.
The suspended particulate matter as it travels from first field to second field
and subsequently so on, the dust density reduces drastically because of
exponential collection efficiencies obtained in each field.
The collected dust will be periodically dislodged through the system known as
“ Tumbling Hammer “ rapping system. In this rapping system , the hammers are
mounted on the shaft with the regular angular displacement in a staggered manner
so as to avoid re-entrainment of dust when it is dislodged from the emitting/collecting
system.
The first field rapping system dislodges the dust approximately 12 raps / hr,
that means the dust is allowed to accumulate over a duration of 5 min and the
O & M MANUAL FOR ESP
CONTENT
rapping takes place instantaneously . Over this 5 min time , the dust is allowed to
form like a cake and it drops down instantly. Similarly the second field is set with 6
raps / hr and subsequent fields also set with different raps / hr and collect the dust as
per field collection efficiencies.
In the event of first field not working , the second field will behave like first field
and the third field will behave like second field and so on . However in the first field,
there will be settlement of dust due to gravity and the quantum of dust collected may
not be equal to that when it was operating. Suppose, if the first field is a dummy field,
about 40% of the dust will get settled due to gravity settling.
Initially the ash handling system vendors are suitably advised to take care of
the above phenomena of ash collection inside the precipitator while designing the
ash evacuation system for ESP hoppers. They are also suitably advised to have
redundancy in ash evacuation system capacity at least for first three/four fields so as
to take care of the above phenomena. They are informed that the ESP hoppers are
only transit storage vessels and NOT STORAGE SILOS. The evacuation must be
PERIODIC and CONTINUOUS.
If the ash evacuation is not working efficiently and periodically, it may lead to
ASH BUILDUP IN THE HOPPERS, especially in the first/second row of hoppers,
where the ash collection is MAXIMUM. This will lead to Initially TRIPPING OF
FIELDS due to dead short. If it is not attended properly, ash evacuation is not
complete and if ash is allowed to buildup it may lead to CATASTROPHIC
COLLAPSE OF STRUCTURES making permanent damage to the total ESP
system.
CONTENT
6.5.6 MAINTENANCE CHECK LIST:-
1. Check the heating elements of insulator compartment for proper functioning.
2. Check the support insulators for any damages or dust accumulation on the
inner surface.
3. Check the insulator compartment for any leakage.
4. Check the discharge rods are available for proper earthing.
5. Check the oil level in transformer.
6. Check the transformer for oil leakage.
7. Check the bus duct connections are proper.
8. Check proper functioning of HT isolator switches.
9. Check the condition of casing insulation and cladding especially near
inspection doors.
10. Check the inspection doors and frames for proper sealing and replace them if
required.
11. Check that there is no corrosion damages appear on the casing walls,
hoppers, inlet and outlet funnels.
12. Check the inlet and outlet funnels for abnormal dust accumulation and also in
internals.
13. Check the collecting electrodes for corrosion.
14. Check all the rapping drives for any abnormal sound and wear of couplings.
15. Check the condition of collecting electrode and emitting electrode rapping
hammers.
16. Check the condition of inlet GD screen rapping hammers.
17. Check all the GD screens and deflector plates are in tact.
18. Check the electrical clearance between collecting and emitting electrode
distance.
19. Check the alignment and straightness of the emitting electrodes and the
discharge frames.
20. Check there is no abnormal dust deposited on collecting and emitting
electrodes.
21. Check all the collecting electrode hammers are properly hitting the shock bar
pads at the center and at suitable height.
22. Check the condition of shock bar pads for any cracks or other damages.
23. Check the condition of shock bar locking arrangement and its location.
24. Check the collecting electrodes for any physical damage.
25. Check the condition of shaft insulator. If required clean the shaft insulator.
26. Check the scavenging screw arrangement in emitting seal box rotates with the
shaft insulator.(for horizontal rapping only)
27. Check the healthiness of shaft insulator heater.
28. Check the gas screen assembly in hopper is in order.
29. Check the healthiness of hopper heaters.
30. Check the bottom of hopper for any corrosion.
31. Check the baffle plates at different locations.
CONTENT
6.6 TROUBLE SHOOTING
6.6.1 Introduction:-
CONTENT
SL. RECOMMENDED REMEDIAL
TYPE OF FAILURE REASON FOR FAILURE
NO. ACTION
CONTENT
Misalignment of emitting
electrode frame work with
Align the emitting system to
respect to collecting system
correct position and replace
after replacement of
the damaged electrode.
insulator or other repair
Electrical erosion of work
04 emitting electrodes
due to heavy sparking Improper rapping resulting Check all the hammers are in
in heavy dust layer over position and properly hitting
electrodes thereby the emitting framework.
increasing sparking Rapping frequency can be
tendency increased suitably.
The ESP should be operated within a maximum spark rate of 12 sparks per minute. It
should be limited to 10 sparks per minute during normal operation. If the ESP has been
worked for a long period it is recommended to replace all the electrodes for better
performance.
CONTENT
Collecting electrode panel Check the shock bar is freely
Collecting electrodes
08 bounded with the shock bar moving inside the shock bar
bend
guide guides.
Mechanical failure of
11 It is rare to happen. Replace the electrode
emitting electrodes
CONTENT
Check welding and seal all the
Improper welding. Leakage
Air in leakage through leaking areas. Cover flange to
15 through cover flange
casing and hopper be properly tightened with
provided in hopper chute.
gasket.
T/ R set readings
TR controller failure, blown
No primary voltage
fuse, shorted SCR circuit, Find the problem and take
19 No primary current
misadjustment of internal remedial action
No secondary current
ground
No secondary voltage
CONTENT
T/ R set readings
High resistance short to
Low primary voltage
ground inside field. Check
Normal primary current
21 for cracked insulators,
Normal secondary
clinker or foreign materials
current
in discharge electrode
Low secondary voltage
T/ R set readings
Problem in controller. Mis-
Low primary voltage
adjustment or
Low primary current
22 malfunctioning of controller.
Low secondary current
Check the T/ R controller
Low secondary voltage
for its settings
No sparking condition
T/ R set readings
High primary voltage
23 No primary current T/ R set secondary opened. Replace T/ R set
No secondary current
CONTENT
Gradual voltage drop Tracking insulators, hopper
28
with increasing current jamming
Cracked HV support
Low secondary voltage
insulator, close internal
31 Low secondary current
electrical clearance,
Sparking condition
Controller problem
CONTENT
Correct the ash handling
Malfunctioning of ash
system, check the hopper
Hopper level high handling system, dust
heaters for proper functioning,
35 indication and the field blocked near discharge
check hopper doors for proper
is being tripped point, air leakage into
sealing and also the cover
hopper, wet dust
flange in side chute.
Excessive corrosion of
Necessary correction works to
casing inside surface The insulation may be
37 be taken. Periodic checking of
due to acid formation insufficient or damaged
insulation to be done.
inside ESP
CONTENT
6.7 SUB VENDORS MANUAL & DATA SHEETS
QUANTITY 28 NOS.
TYPE RF TYPE
MODEL RF – 550
INDICATOR DIGITAL
PROBE
MODEL RF-550 RT CB
ELECTRONIC UNIT
MODEL RF-550 RT EC
SUPPLIER’S ADDRESS:
M/S EIP ENVIRO LEVEL CONTROLS PVT.LTD.
B-130, SECTOR-X,NOIDA - 201301,UTTAR PRADESH.
CONTENT
INSTALLATION OPERATION
&
MAINTENANCE MANUAL
RF LEVEL SWITCH
MODEL : 550
1
CONTENT
CONTENTS
I. INTRODUCTION 1
A. Application
B. Control Configuration
C. Equipment Specification
II. INSTALLATION 4
A. Receiving & Inspection
B. Electronic Transmitter
C. Sensing Probe
D. Electronic Protector
E. Wiring
III. OPERATION 7
A. Start-Up
B. Calibration
IV. MAINTENANCE 8
A. Normal
B. Trouble Shooting
C. Manufacturer Assistance
V. DRAWINGS
VI. APPENDIX
A. Installation Check Points
B. Complaint Format
C. Installation Tips
D. Application Data Sheet for future / additional requirements
or new applications
2
CONTENT
LEVEL SWITCH
FOR GRANULAR MATERIALS & LIQUIDS
1. INTRODUCTION
A. APPLICATION
The instruction in this manual pertain to the Model -550 Level Control based on
Radio Frequency principle capable of monitoring the level of material present in a
vessel at a preset point. The relay contacts may then be used to operate other
devices.
The Model - 550 point level control utilises an electronics to provide Precision
Reliability Independent of Moisture material temperature, Coating Transit
material Suspended dust etc., meaning thereby it can be used with wide variety
of materials which may be conductives, non conductive solids, liquids, corrosive
or even tend to coat on the sensing probe can be accurately measured and
controlled.
A. CONFIGURATION
RF signal provided to the probe varies with the change of media (the application
material having interparticle cohesive contact) upto the vessel body as reference
ground. The material in transit or the suspended particles which do not have
cohesive intraparticle contact upto the vessel shell are ignored. The vessel part
selected for the probe mounting does not act as reference ground, as long as
shield section is placed physically between active section of the probe and vessel
body part where the probe is mounted. The variation in RF signal is utilised to
activate a relay and its contacts are available as output for further use. To protect
the equipment from electrostatic charge developed in the vessel/hopper an
Electrostatic Charge Protector is provided in the Probe Head.
3
CONTENT
B. EQUIPMENT SPECIFICATION
2. SENSING PROBE
4
CONTENT
3. PROBE HEAD
For use with SWITCH Model Probes
4. ELECTROSTATIC PROTECTOR
5
CONTENT
II. INSTALLATION
B. ELECTRONIC CONTROLLER
1. UNIT LOCATION
2. CABLE CONNECTION
Make cable connection as per drawing enclosed (as part of this manual) in
section V. etc. and ensure that there is no chance of damage /
disconnection/shorting of cable/cable connection in future.
6
CONTENT
C. PROBE (IMPORTED)
7
CONTENT
D. ELECTROSTATIC CHARGE PROTECTOR
E. WIRING
1. PROBE CABLES
♦ CABLE EIP provides coaxial cable for
connection of electronic unit to probe.
♦ Termination Hook-up of the probe cable requires
connections of the three cable
conductors centre wire (CW) to “PR”,
Middle layer (MW) to “SH” and Top
Layer Drain wire (DW) to “G” at both
electronic controller and probe. Refer
the Drawing in Section V.
2. POWER CONNECTIONS
Power connections (as specified) as made directly to the terminal blocks located
in electronic controller. Due to the low power consumption of the unit, (3VA) light
gauge wiring of size 1.0mm sq. may be sufficient. However, consult the local
Electrical Regulations for exact wire guage selection.
3. OUTPUT CONNECTION
Output relay connections are made directly to the terminal blocks located inside
the electronic controller. These relay contacts (two numbers change over
potential free contacts) are rated for 5Amp at 220 VAC non-inductive or as
specified. Output wiring should be compatible with the intend output load (less
than relay contact rating)
8
CONTENT
III. OPERATION
A. START-UP
1. ELECTRONIC UNIT
1. Ambient condition suitable (-10 to+60 Deg. C. Max.).
2. Electronic unit installed at convenient man height.
3. Electronic Unit not exposed to direct sunlight, rain or snow.
4. Fasteners tightened properly.
5. Earthing grid connected at both the earthing terminals of electronic unit.
6. Supply voltage is as specified on the terminals.
7. Cable used from electronic unit to probe is EIP supplied/EIP specified Cable
length from Electronic Unit to probe is less than 25 Mtrs. Centre wire
connected to “PR”, middle layer to “SH” & top layer/drain wire to “G” at both
ends.
8. Glands used for cables are proper.
9. Proper Lugs are provided at both ends of the cable.
10. Proper Dressing of cable done with cable tray/conduct for all the cables to
ensure no disconnection / damage in future.
2. PROBE
1. Probe Mounted 90 (+/-) 15 Deg to vessel wall / plate
2. No Pipe cover/Hood/Canopy inside vessel over/near probe.
3. Maximum gap from other walls / any other metal parts.
4. Shield section projection inside the vessel more than 25mm (1”)
5. If flexible probe mounted from top only and distance from fill point less than
length of the probe.
6. If flushed probe : either flush with inner surface of the vessel or projects
inside upto 5mm (all around the probe).
7. Verify probe ground terminal shows firm continuity with vessel / vessel
structure earthing grid.
Switch on the appreciated supply voltage and yellow & either green or red local
indications glow.
9
CONTENT
B. CALIBRATION
The instrument has been factory calibrated for use in the majority of
applications, However, due to variations in installations, it is advisable to
field verify this setting. This may be accomplished using the following
procedure. For maximum accuracy, all calibration adjustments should be
made with the vessel/hopper at operating conditions.
Check local indications LED (Green or Red) Green LED should glow, if not
turn adjustment clockwise (CW) so that green LED glow and Red LED
glows off.
Turn the turning adjustments counter-clockwise (ccw) counting the number
of revolutions until the local indication LED just glows Red.
Turn the adjustment clockwise (cw) slowly until the local indication LED just
glows Green.
IV. MAINTENANCE
A NORMAL
The EIP SWITCH models are designed for years of maintenance-free service.
This is ensured by use of no moving parts in the unit except the output relay and
there is no electronics or any sensitive part in the sensing probe.
10
CONTENT
B. TROUBLE SHOOTING
1. ELECTRONIC CONTROLLER
The above values should read with in 2 to 5 VDC Value (I) should read 5 to
10% less than value (ii)
a. If you were unable to get required results “e” and “g” above then there is fault
in the electronic unit. It is recommended that the electronic controller be
returned to EIP for repair see Section VC.
2. PROBE
11
CONTENT
i) Probe to ground ………………………….. VDC
ii) Shield to ground ………………………….. VDC
Both should read within 10% of the values attained in b.
d. If measurements obtained in 2b & 2c are as they should be ie within 10% of
the values obtained in 1 B1g verify calibration as per Section III C.
e. If measurement are not as they should be, proceed to f & B3.
f. Disconnect cable at probe also remove the electrostatic protector (with probe
still in its position, mounted on the hopper). With the VOM in the resistance
scale, measure the following probe values.
Probe uncovered with material
Probe to shield …………………………….. OHMS
Shield to ground……………………………..OHMS
Probe to ground …………………………….OHMS
All above values should read above 1M Ohms, if not, remove the probe from its
position and repeat 4B2f if values are above 1 Mohms check installation as per
3b2, if not, proceed to IV C.
3. PROBE CABLE
12
CONTENT
4. OUTPUT CIRCUITRY
The output circuit of the instrument consist of two sets change over contacts
brought out to terminal blocks. These contacts open and close in response to
material level change. Relay operation may generally be heard as an audible
“click” Relay operation can also be checked placing VOM, set on resistance
scale between terminal block points on NC and COM. The VOM reading should
change from OHMS to infinity when material contacts the probe or when the
probe terminal “PR” is touched with finger, and change of local indication LED
from Green to Red.
C. ASSISTANCE
If problems exist other than those mentioned above or if the attempts to locate
the problems fail, call the EIP factory and ask for the service department at the
following address with details of the problem faced in the complaint format issued
included in this manual Appendix B by EIP further guidance/deputation of
representative for attending the problems.
13
CONTENT
CONTENT
CONTENT
CONTENT
CONTENT
6.7.2 TRANSFORMER RECTIFIER SET
DESCRIPTION SPECIFICATION
MAKE M/s. HIND RECTIFIERS LTD,
QUANTITY 14 NOS.
APPLICATION TR SET FOR ESP
TYPE STEP UP DOUBLE WOUND
INPUT VOLTAGE 415 V, ±10%, SINGLE PHASE, 50 Hz
OUTPUT VOLTAGE 95 KV PEAK
OUTPUT CURRENT 1400 mA MEANS
DUTY CONTINUOUS
TEMPERATURE RISE OVER AMBIENT 50°C
CLASS OF BUSHING 52 KV, AC
RECTIFIER TYPE FULL WAVE BRIDGE RECTIFIER WITH POSITION
TERMINAL EARTHED AND NEGATIVE TERMINAL
BROUGHT OUT THROUGH SINGLE BUSHING
CONTROL BY MEANS OF SCR
TRANSFORMER RECTIFIER CONTROL UNIT:
TYPE OF CABINET FREE STANDING
VOLTAGE CONTROL PROVIDED
7ARC SUPPRESSION PROVIDED
PROTECTION IP 51
INSTRUMENTATION PROVIDED AS PER SUPPLIER STANDARD
SIGNAL CIRCUIT PROVIDED
VENTILLATION PROVIDED
DESIGN AMBIENT TEMPERATURE 50°C
POWER SUPPLY 415 V AC, 3 PHASE, 50 Hz
INSTALLATION
- TR SET OUTDOOR
- CONTROL CUBICLE INDOOR
CONTROL SUPPLY 110 V AC
SUPPLIER’S ADDRESS:
M/s. HIND RECTIFIERS LTD,
LAKE ROAD , BHANDUP(W), MUMBAI - 400 078.
CONTENT
(BOILER – BJ059 & BJ060) DATA SHEET
DESCRIPTION SPECIFICATION
GENERAL DATA:
QUANTITY 14 NOS.
FIELD TR SET.
SIDE.
HANDLE MANUAL
SUPPLIER’S ADDRESS:
M/s. ASSOCIATED POWERCONEQUIPMENT (INDIA) PVT LTD,
7,ELECTRONIC ESTATE ,
PUNE – SATARA ROAD,
PUNE-411 009.
CONTENT
/// POWERCON PAGE 1 OF 17
CONTENT
/// POWERCON PAGE 2 OF 17
CONTENT
/// POWERCON PAGE 3 OF 17
CONTENT
/// POWERCON PAGE 4 OF 17
CONTENTS
ATTENTION
IMPORTANT INSTRUCTIONS
INTRODUCTION
CONTENT
/// POWERCON PAGE 5 OF 17
ATTENTION
Unpack the equipment carefully. Do not use iron bars for this purpose as this may cause
damage to the equipment. Make through physical inspection of the equipment. This
checking should be made with reference to the packing slip.
The earthing of the equipment i.e. Electronic Control Cubicle and Transformer Rectifier
is very essential and has to be as per the standards. This is required because the
equipment is a high voltage equipment and protection of operating personnel can be
ensured only with good earthing.
CONTENT
/// POWERCON PAGE 6 OF 17
///POWERCON
IMPORTANT INSTRUCTIONS
1.As soon as the equipment is received at site , the same should be unpacked carefully and
should be checked as per the packing slip and for transit damages should be reported to the
concerned authority immediately.
2.The equipment should be handled carefully and stored properly as per instructions given
in the manual. M/s. Associated Powercon Equipment (I) Pvt.Ltd. Is not responsible for
damage caused by improper storage, mis-handling and pilferage.
3.Erection and commissioning should be done. Strictly in accordance with instructions and
procedure given in the manual.
4.Operations should read the manual carefully. They should also read related literature to
understand the equipment better.
5.User of the equipment shall ensure that he has enough spares for regular maintenance for
the equipment. This will reduce shut down period.
6.Equipment should be operated properly and in accordance with instructions given in the
manual.
8.In case the user requires services of manufacturers engineers a detailed report of
problems aced should be sent to the above address for correct spares and prompt services.
CONTENT
/// POWERCON PAGE 7 OF 17
INTRODUCTION
The atmosphere at industrial locations such as cement plant, steel plant. Thermal
power stations etc. where large sized coal fired boilers are used, contain high volume of
dust, which decides impairing functional efficiency of mechanical and electrical
equipment, poses a health hazard. The dust issuing out from the exhaust of these plants,
can most effectively be prevented from entering into atmosphere by employing
Electrostatic Precipitation technique.
HT switch is used for disconnect the connection between transformer and ESP field
It is used for safety purpose in all power plant. Where the ESP is used.
It will protect the human being from high voltage which is develop in the ESP field
when the transformer is charged
The High Voltage DC supply equipment described in this manual is designed to suit
the requirements of Electrostatic Precipitators, for various applications. Some of the
applications of ESP's for which this equipment can be used are mentioned below .
CONTENT
/// POWERCON PAGE 8 OF 17
when the position of earth switch on HT ON at that time the moving insulator is come
to insulator 1 then the ESP transformer connection is connected to ESP field.
When the position of earth switch on ground at that time the moving insulator lever is
connected to the earth clamp.The ESP field get discharge by the HT disconnected
switch.
CONTENT
/// POWERCON PAGE 9 OF 17
CONTENT
/// POWERCON PAGE 10 OF 17
CONTENT
/// POWERCON PAGE 11 OF 17
HT DISCONNECT SWITCH
2
1
CONTENT
/// POWERCON PAGE 12 OF 17
1
2
1) FIXED INSULATOR-1
2) FIXED INSULATOR-2
3) MOVING INSULATOR
Both Fix insulator and earth clamp which is fitted on bottom side of the duct is must be
earth by earth bolt M6
CONTENT
/// POWERCON PAGE 13 OF 17
In above figure shown when the position of earth switch on HT ON at that time field is connected
to TR SET
CONTENT
/// POWERCON PAGE 14 OF 17
In above figure shown when position of earth switch is on ground at that time
The ESP field get discharge by the HT disconnected switch.
CONTENT
/// POWERCON PAGE 15 OF 17
1) FIELD DISCHARGE
1 – In above figure Shown when earth switch is on ground that time lever is
connected to earth clamp by moving insulator .
The ESP field get discharge by the HT disconnected switch.
CONTENT
/// POWERCON PAGE 16 OF 17
Bradeded copper wire connect between fix insulator of ESP field side and moving
insulator as shown in above figure.
1- In above figure show the moving insulator is come to insulator 2 then the ESP
transformer connection is connected to ESP field.
CONTENT
/// POWERCON PAGE 17 OF 17
Earth clamp which is fitted on bottom side of the duct is must be earth by earth
bolt M6
CONTENT
/// POWERCON PAGE 1 OF 17
CONTENT
/// POWERCON PAGE 2 OF 17
CONTENT
/// POWERCON PAGE 3 OF 17
CONTENT
/// POWERCON PAGE 4 OF 17
CONTENTS
ATTENTION
IMPORTANT INSTRUCTIONS
INTRODUCTION
CONTENT
/// POWERCON PAGE 5 OF 17
ATTENTION
Unpack the equipment carefully. Do not use iron bars for this purpose as this may cause
damage to the equipment. Make through physical inspection of the equipment. This
checking should be made with reference to the packing slip.
The earthing of the equipment i.e. Electronic Control Cubicle and Transformer
Rectifier is very essential and has to be as per the standards. This is required because
the equipment is a high voltage equipment and protection of operating personnel can
be ensured only with good earthing.
CONTENT
/// POWERCON PAGE 6 OF 17
///POWERCON
IMPORTANT INSTRUCTIONS
1.As soon as the equipment is received at site , the same should be unpacked carefully and
should be checked as per the packing slip and for transit damages should be reported to the
concerned authority immediately.
2.The equipment should be handled carefully and stored properly as per instructions given
in the manual. M/s. Associated Powercon Equipment (I) Pvt.Ltd. Is not responsible for
damage caused by improper storage, mis-handling and pilferage.
3.Erection and commissioning should be done. Strictly in accordance with instructions and
procedure given in the manual.
4.Operations should read the manual carefully. They should also read related literature to
understand the equipment better.
5.User of the equipment shall ensure that he has enough spares for regular maintenance for
the equipment. This will reduce shut down period.
6.Equipment should be operated properly and in accordance with instructions given in the
manual.
8.In case the user requires services of manufacturers engineers a detailed report of
problems aced should be sent to the above address for correct spares and prompt services.
CONTENT
/// POWERCON PAGE 7 OF 17
INTRODUCTION
The atmosphere at industrial locations such as cement plant, steel plant. Thermal
power stations etc. where large sized coal fired boilers are used, contain high volume of
dust, which decides impairing functional efficiency of mechanical and electrical
equipment, poses a health hazard. The dust issuing out from the exhaust of these plants,
can most effectively be prevented from entering into atmosphere by employing
Electrostatic Precipitation technique.
HT switch is used for disconnect the connection between transformer and ESP field
It is used for safety purpose in all power plant. Where the ESP is used.
It will protect the human being from high voltage which is develop in the ESP field
when the transformer is charged
The High Voltage DC supply equipment described in this manual is designed to suit
the requirements of Electrostatic Precipitators, for various applications. Some of the
applications of ESP's for which this equipment can be used are mentioned below .
CONTENT
/// POWERCON PAGE 8 OF 17
when the position of earth switch on HT ON at that time the moving insulator is come
to insulator 1 then the ESP transformer connection is connected to ESP field.
When the position of earth switch on ground at that time the moving insulator lever is
connected to the earth clamp.The ESP field get discharge by the HT disconnected
switch.
CONTENT
/// POWERCON PAGE 9 OF 17
CONTENT
/// POWERCON PAGE 10 OF 17
CONTENT
/// POWERCON PAGE 11 OF 17
HT DISCONNECT SWITCH
1 2
CONTENT
/// POWERCON PAGE 12 OF 17
2
1
1) FIXED INSULATOR-1
2) FIXED INSULATOR-2
3) MOVING INSULATOR
Both Fix insulator and earth clamp which is fitted on bottom side of the duct is must be
earth by earth bolt M6
CONTENT
/// POWERCON PAGE 13 OF 17
In above figure shown when the position of earth switch on HT ON at that time field is connected
to TR SET
CONTENT
/// POWERCON PAGE 14 OF 17
In above figure shown when position of earth switch is on ground at that time
The ESP field get discharge by the HT disconnected switch.
CONTENT
/// POWERCON PAGE 15 OF 17
1) FIELD DISCHARGE
1 - In above figure Shown when earth switch is on ground that time lever is
connected to earth clamp by moving insulator.
The ESP field get discharge by the HT disconnected switch.
CONTENT
/// POWERCON PAGE 16 OF 17
Bradeded copper wire connect between fix insulator of ESP field side and moving
insulator as shown in above figure.
1- In above figure show the moving insulator is come to insulator 1 then the ESP
transformer connection is connected to ESP field.
CONTENT
/// POWERCON PAGE 17 OF 17
Earth clamp which is fitted on bottom side of the duct is must be earth by earth
bolt M6
CONTENT
(BOILER – BJ059 & BJ060) DATA SHEET
DESCRIPTION SPECIFICATION
GENERAL DATA:
QUANTITY 4 NOS.
MATERIAL OF CONSTRUCTION
CLAMP S.S.
SUPPLIER’S ADDRESS:
M/s. NATIONAL ENGINEERS,
DAKSHIN BARASAT STATION ROAD,
N. KALIKAPORE (NEAR CHANDHI GANGA),
P.O. DAKSIN BARASAT, 24, PARGANAS
(S),N. Kalikapore,
WEST BENGAL.
CONTENT
6.7.5 MECHANICAL SAFETY INTERLOCK
DESCRIPTION SPECIFICATION
GENERAL DATA:
QUANTITY 2 NOS.
C KEY EXCHANGE BOX HAVING SEVEN FRONT LOCK WITH KEY AND 1
F KEY EXCHANGE BOX HAVING FOUR FRONT LOCK WITH KEY AND 1
G KEY EXCHANGE BOX HAVING TWO FRONT LOCK WITH KEY AND 1
H KEY EXCHANGE BOX HAVING NINE FRONT LOCK WITH KEYS AND 1
K KEY EXCHANGE BOX HAVING SEVEN FRONT LOCK WITH KEY AND 1
KEY
CONTENT
OPERATION & INSTRUCTION
MANUAL OF
INTERLOCKING SYSTEM
FOR ESP
ENTERPRISING ENGINEERS
46-47, A SECTOR INDUSTRIAL AREA, GOVINDPURA,
BHOPAL- 462 023 (M.P.) - INDIA
CONTENT
.. 2 ..
CONTENT
... 3 ...
(iii) Door Lock (DT Body with chain arrangement)_ : (Fig.3)
This interlock consists of two separate parts. One part is the basic interlock
fixed on a Brass/Aluminum Body, housing the mechanism. Another part is a
sliding Bolt. When the sliding bolt is inserted and rotated in the main body,
the key is released and the sliding bolt will remain trapped in the main body.
To release the sliding bolt, the key should be inserted in the lock and
rotated. This will release the bolt and trap the key.
In its simplest form, a control key is trapped until all other keys have been
returned to their respective exchange box locks and turned to their trapped
positions. The control key can then be removed, trapping all other keys.
(v) Door Enclosure Box :
Number of such key-exchange boxes are kept in steel door enclosure box
as required. The design of this box has been tested at CPRI Bhopal and it
ensures IP 55 protection.
(i) Operation :
Switch off the lock switches of all the rectifier transformers, which will
open them and will release the keys with different inscriptions. The switch
will remain in OFF position and can be put in ON position only when the
keys are available.
(ii) These keys are then inserted in corresponding DT Body with chain
arrangement door locks of disconnecting switches and rotated. Now these
keys will be trapped in the locks and the sliding bolts released. Now the
disconnecting switch is to be brought to OFF position. Then the sliding both
are inserted and rotated bolts in DT Body with chain arrangement door locks.
The sliding bolts will be trapped and the keys will be released.
Contd..4
CONTENT
...4...
(iii) All the above keys are inserted in the key exchange box of Earthing Field
and rotated, which will trap the keys. The Field is earthed and the
Multiplication control key is released.
(iv) These Multiplication control key is then inserted in another key exchange
box which accommodates all the Multiplication Control keys of different
inspection doors. The Multiplication Control key is trapped when rotated,
releasing all other Multiplication Control keys of inspection doors.
(v) These Multiplication Control keys are then inserted in corresponding key
exchange boxes and rotated. Now the Multiplication Control keys are trapped
in key exchanges boxes and the keys of inspection doors are released.
(vi) Insert these keys in the DT Body with chain arrangement type interlocks of
doors and rotate. These keys will be trapped and the sliding bolts will be
released by rotating them. Now the different inspection doors can be
opened.
Now all the field earth switches are put to ON position. The Control key is
trapped and the keys of disconnecting switch DT Body with chain
arrangement locks are released. These keys are then inserted and the
disconnecting switches brought to ON position which will release the keys
of front locks of Key Exchange Box's. Insert there keys in the front lock of
respective KEB & Rotated. Then the control keys of there KEB's will be
released. These keys are then inserted in the rotary switches & the rectifier
transformers are closed.
Contd..5
CONTENT
...5...
(i) While operating the interlock, inscription of lock and key should be
matched.
(ii) In case of Key Exchange Box, when the end lock is to be operated, the
front keys should be in fully trapped position. This will enable the end
key to operate smoothly.
(iii) Mechanical Interlocks are so designed that the releasing or trapping is very
smooth. Thus in proper conditions no extra force is required for operating the
locks. If key is not rotating DO NOT APPLY EXTRA FORCE, which
may damage the mechanism or the locks. Instead check that :
(5) CONCLUSION :
Thus interlocking devices can be used in different applications to
ensure particular sequence of operation for the safety of personnel and
equipments. If correct type of interlocks are selected and mounted
properly these can provide a fool-proof and safe system.
*****
CONTENT
(BOILER – BJ059 & BJ060) DATA SHEET
HEATERS
DESCRIPTION SPECIFICATION
GENERAL DATA:
INSULATORS(THERMOSTATICALLY CONTROLLED)
RATED POWER 1 KW
CONTENT
CONTENT
INSTALLATION, OPERATION & MAINTENANCE MANUAL FOR
SUPPORT INSULATOR HEATER
SAFETY ASPECTS
USE OF EQUIPMENT:
The equipment should only be used by qualified & experienced operators and engineers
according to the instruction stated herein. The equipment has U-Shaped (circular) heating element
fitted through nipple on heater flange . Entry box has Al Die cast enclosure with IP-55 enclosure,
which has been designed, manufactured by M/s ESCORTS LIMITED, Faridabad.
INSTALLATION
Incoming Inspection
Upon receiving the equipment check to see that no damage has occurred during transport and if
all the parts are intact (see drawings & Bill of materials). Should you perceive anything wrong,
please notify your transporter, Insurance Company and us at the following address:
PHONE – 0129-2576344,6319
FAX NO.- 0129- 2232148
Email; gs.johar@escortsed.com, cn.chaubey@escortsed.com
Check for any physical damage to the heating element terminals, porcelain insulators, connection
terminals, interconnecting cables, thermocouples, thermostat etc. In case of any damage, do not
install unless it is repaired.
CONTENT
Mains Voltage
Kindly refer the drawing, enclosed, which show the construction of the equipment. The heating
unit consists of U shaped circular heating elements fitted through on heater flange. Heating
elements are connected in Single phase.
FUNCTIONAL TESTING
The electrical performance and safety of the equipment is checked throughout its production and
before leaving factory. However since Magnesium oxide powder used as insulation in the heating
elements is hygroscopic ( has the tendency to absorb moisture), inspite of best sealing methods
adopted by us, it may so happen in some case that heating unit may show low I.R value after
prolonged storage. It may be possible that only one heating element may have low I.R value but
since all the heaters are interconnected the whole unit will show low I.R value
Please carryout the following test on the heating unit :
Install the heating unit at requisite site. Make electrical connections of incoming cable using
cable of appropriate rating with crimping type copper lugs & cable glands provided on the
cable entry box.
CONTENT
OPERATION
Before switching ON the heating unit ensures flow of medium to be heated in the
heating unit and that the heating elements are fully immersed in the medium.
Ensure supply voltage to the heating unit is as per the design specifications.
Check that the heating unit is drawing the rated current.
MAINTENANCE
Disconnect powers supply before opening terminal box or junction box.
Electrical connections in the heating terminal box and junction box should be checked and
tightened regularly.
Any damage to the heating element terminals or porcelain insulator should be repaired
immediately.
GUARANTEE & SERVICE
We are responsible for the trouble free working of the equipment only when,
All repairs, changes, modifications have been carried out by authorized persons only
The electrical installation is carried out as per the Indian Electricity rules & proper earthing is
ensured.
The equipment is used for the purpose for which it has been designed.
Maintenance of the equipment is carried out regularly & in the manner prescribed.
Incorrect use of the equipment or failure to carry out maintenance according to instructions
exonerates M/S Escorts Limited or their representative or suppliers from all liability for any
resulting damage, injury, defect or malfunction. The guarantee expires when the equipment is not
used in accordance with the above mentioned conditions.
NOTE:
1. Appropriate size of cables and explosion proof cable glands should be fitted. All unused
holes must be plugged properly. Any un-pluged hole or improper gland usage may
cause an explosion.
2. After connecting the incoming and outgoing cables the bolts for the cover should be
tightened within the limit and ensures that all the bolts are fitted at all the places
specified. Any missing or loose bolt may result in an explosion.
****************
CONTENT
6.7.7 SHAFT INSULATOR HEATER
QUANTITY 14 NOS
RATED POWER 1 KW
CONTENT
INSTALLATION, OPERATION & MAINTENANCE MANUAL FOR
SHAFT INSULATOR
SAFETY ASPECTS
USE OF EQUIPMENT:
The equipment should only be used by qualified & experienced operators and engineers
according to the instruction stated herein. The equipment has U-Shaped (M-Type) heating
element Brazed with 498x65x10mm thick MS Plate has Al Die cast enclosure with IP-55
enclosure, which has been designed, manufactured by M/s ESCORTS LIMITED, Faridabad.
INSTALLATION
Incoming Inspection
Upon receiving the equipment check to see that no damage has occurred during transport and if
all the parts are intact (see drawings & Bill of materials). Should you perceive anything wrong,
please notify your transporter, Insurance Company and us at the following address:
PHONE – 0129-2576344,6319
FAX NO.- 0129- 2232148
Email; gs.johar@escortsed.com, cn.chaubey@escortsed.com
Check for any physical damage to the heating element terminals, porcelain insulators, connection
terminals, interconnecting cables, thermocouples, thermostat etc. In case of any damage, do not
install unless it is repaired.
CONTENT
Mains Voltage
Kindly refer the drawing, enclosed, which show the construction of the equipment. The heating
unit consists of U shaped heating elements brazed Brazed with 498x65x10mm thick MS Plate.
Heating elements are connected in Single phase.
FUNCTIONAL TESTING
The electrical performance and safety of the equipment is checked throughout its production and
before leaving factory. However since Magnesium oxide powder used as insulation in the heating
elements is hygroscopic ( has the tendency to absorb moisture), inspite of best sealing methods
adopted by us, it may so happen in some case that heating unit may show low I.R value after
prolonged storage. It may be possible that only one heating element may have low I.R value but
since all the heaters are interconnected the whole unit will show low I.R value
Please carryout the following test on the heating unit :
Install the heating unit at requisite site. Make electrical connections of incoming cable using
cable of appropriate rating with crimping type copper lugs & cable glands provided on the
cable entry box.
CONTENT
OPERATION
Before switching ON the heating unit ensures flow of medium to be heated in the
heating unit and that the heating elements are fully immersed in the medium.
Ensure supply voltage to the heating unit is as per the design specifications.
Check that the heating unit is drawing the rated current.
MAINTENANCE
Disconnect powers supply before opening terminal box or junction box.
Electrical connections in the heating terminal box and junction box should be checked and
tightened regularly.
Any damage to the heating element terminals or porcelain insulator should be repaired
immediately.
GUARANTEE & SERVICE
We are responsible for the trouble free working of the equipment only when,
All repairs, changes, modifications have been carried out by authorized persons only
The electrical installation is carried out as per the Indian Electricity rules & proper earthing is
ensured.
The equipment is used for the purpose for which it has been designed.
Maintenance of the equipment is carried out regularly & in the manner prescribed.
Incorrect use of the equipment or failure to carry out maintenance according to instructions
exonerates M/S Escorts Limited or their representative or suppliers from all liability for any
resulting damage, injury, defect or malfunction. The guarantee expires when the equipment is not
used in accordance with the above mentioned conditions.
NOTE:
1. Appropriate size of cables and explosion proof cable glands should be fitted. All unused
holes must be plugged properly. Any un-pluged hole or improper gland usage may
cause an explosion.
2. After connecting the incoming and outgoing cables the bolts for the cover should be
tightened within the limit and ensures that all the bolts are fitted at all the places
specified. Any missing or loose bolt may result in an explosion.
****************
CONTENT
6.7.8 HOPPER HEATER
QUANTITY 336 NOS.
CONTROLLED)
SUPPLIER’S ADDRESS:
M/s. ESCORTS LTD,
PLOT NO 115,SECTOR-24,
FARIDABAD,HARYANA-121005.
CONTENT
CONTENT
INSTALLATION, OPERATION & MAINTENANCE MANUAL FOR
HOPPER HEATER
SAFETY ASPECTS
USE OF EQUIPMENT:
The equipment should only be used by qualified & experienced operators and engineers
according to the instruction stated herein. The equipment has U-Shaped heating element Brazed
with CI Adopter. Entry box has Al Die cast enclosure with IP-55 enclosure , which has been
designed, manufactured by M/s ESCORTS LIMITED, Faridabad.
INSTALLATION
Incoming Inspection
Upon receiving the equipment check to see that no damage has occurred during transport and if
all the parts are intact (see drawings & Bill of materials). Should you perceive anything wrong,
please notify your transporter, Insurance Company and us at the following address:
PHONE – 0129-2576344,6319
FAX NO.- 0129- 2232148
Email; gs.johar@escortsed.com, cn.chaubey@escortsed.com
Check for any physical damage to the heating element terminals, porcelain insulators, connection
terminals, interconnecting cables, thermocouples, thermostat etc. In case of any damage, do not
install unless it is repaired.
CONTENT
Mains Voltage
Kindly refer the drawing, enclosed, which show the construction of the equipment. The heating
unit consists of U shaped heating elements brazed with CI Adopter. Heating elements are
connected in Single phase.
FUNCTIONAL TESTING
The electrical performance and safety of the equipment is checked throughout its production and
before leaving factory. However since Magnesium oxide powder used as insulation in the heating
elements is hygroscopic ( has the tendency to absorb moisture), inspite of best sealing methods
adopted by us, it may so happen in some case that heating unit may show low I.R value after
prolonged storage. It may be possible that only one heating element may have low I.R value but
since all the heaters are interconnected the whole unit will show low I.R value
Please carryout the following test on the heating unit :
Install the heating unit at requisite site. Make electrical connections of incoming cable using
cable of appropriate rating with crimping type copper lugs & cable glands provided on the
cable entry box.
CONTENT
OPERATION
Before switching ON the heating unit ensures flow of medium to be heated in the
heating unit and that the heating elements are fully immersed in the medium.
Ensure supply voltage to the heating unit is as per the design specifications.
Check that the heating unit is drawing the rated current.
MAINTENANCE
Disconnect powers supply before opening terminal box or junction box.
Electrical connections in the heating terminal box and junction box should be checked and
tightened regularly.
Any damage to the heating element terminals or porcelain insulator should be repaired
immediately.
GUARANTEE & SERVICE
We are responsible for the trouble free working of the equipment only when,
All repairs, changes, modifications have been carried out by authorized persons only
The electrical installation is carried out as per the Indian Electricity rules & proper earthing is
ensured.
The equipment is used for the purpose for which it has been designed.
Maintenance of the equipment is carried out regularly & in the manner prescribed.
Incorrect use of the equipment or failure to carry out maintenance according to instructions
exonerates M/S Escorts Limited or their representative or suppliers from all liability for any
resulting damage, injury, defect or malfunction. The guarantee expires when the equipment is not
used in accordance with the above mentioned conditions.
NOTE:
1. Appropriate size of cables and explosion proof cable glands should be fitted. All unused
holes must be plugged properly. Any un-pluged hole or improper gland usage may
cause an explosion.
2. After connecting the incoming and outgoing cables the bolts for the cover should be
tightened within the limit and ensures that all the bolts are fitted at all the places
specified. Any missing or loose bolt may result in an explosion.
****************
CONTENT
(BOILER – BJ059 & BJ060) DATA SHEET
6.7.9 THERMOSTAT
DESCRIPTION SPECIFICATION
GENERAL DATA:
INSULATOR HEATERS
TYPE ON / OFF
HEATERS
TYPE ON / OFF
SUPPLIER’S ADDRESS:
M/s. RESEARCH NEEDS.,
159, GOVINDAPPA STREET,CHENNAI,
TAMILNADU-600001.
CONTENT
(BOILER – BJ059 & BJ060) DATA SHEET
6.7.10 RAPPING GEARED MOTOR
DESCRIPTION SPECIFICATION
GENERAL DATA:
MAKE M/S. POWER BUILD
QUANTITY 16 NOS.
ENCLOSURE TEFC
DEGREE OF PROTECTION IP 65
TYPE)
LOCATION OUTDOOR
SUPPLIER’S ADDRESS:
CONTENT
(BOILER – BJ059 & BJ060) DATA SHEET
DESCRIPTION SPECIFICATION
GENERAL DATA:
MAKE M/S. POWER BUILD
QUANTITY 14 NOS.
ENCLOSURE TEFC
DEGREE OF PROTECTION IP 65
TYPE)
LOCATION OUTDOOR
SUPPLIER’S ADDRESS:
CONTENT
INSTRUCTION MANUAL
FOR
HELICAL INLINE GEARED
MOTORS/REDUCERS
FOOT MOUNTED
AGITATOR TYPE
We are pleased to enter your name in our customers list and greatly appreciate your
decision in selecting PBL Geared Motors/Gear Speed Reducers.
This instruction manual covers some essential procedures for installation, operation and
maintenance. Before operating the unit, you should first thoroughly read this manual.
During the warranty period, the geared motors/reducers must not be opened without our
consent, lest warranty will be forfeited. We do not honour any claims raised during the
warranty period, which would arise from alterations or repairs carried out without our
consent.
1.1 the items indicated on the nameplate are in conformance with your requirements.
1.2 there is no damage to the unit due to humidity or dirt accumulated in transit.
1.3 operating conditions of driven machine (load, frequency of start and degree of
shock) do not differ from the ones indicated at the time of order. Please contact PBL
if there is any deviation.
2. STORAGE
2.1 In case geared motors/reducers are to be stored duly packed, for a long period of
time:
(a) Geared motors/reducers have to be stored Indoor or the clean and dry place,
where there is no vibration and major changes in temperature.
(b) Rotate shaft by hand every 3 months to prevent bearing from rusting; confirm
that shaft rotates smoothly and there is no abnormal noise.
(c) Check the insulation resistance with insulation resistance tester of 500V
every 3 months and make sure that the value is more than 1M
2.2 In case geared motors/reducer are stored after installation with machine for along
period of time (over 6 months in general condition, over 3 months in hot and humid
place) :
1
CONTENT
(a) If geared motors/reducers are exposed to high humidity or if there is
possibility water or foreign particle to enter in the units, cover geared
motors/reducers with polyethylene sheet.
(b) Run geared motors/reducers for about 5 minutes every 3 months to prevent
bearing from rusting.
(c) Before operation, check the insulation resistance, inspect bearing and the
connection to power supply source, etc. to see that there is no abnormality.
3. Tips on Installation
3.1 When installing the Geared Motors/Reducers, make sure that the foundations
or the base frames do not notably tend to vibrate. The load-bearing surfaces, base
plates or flanges, should bear the weight uniformly, and be properly tightened.
3.2 Belt pulleys, couplings or gears, which are to be fitted to the output shaft, must have
a bore of ISA fit H7. Remove machining burrs if at all on the bore. Apply thin film of oil
on shaft and fit transmission part by means of a pull-on device which may be
screwed into the tapped hole in the shaft stub. It is advisable to heat the part prior
to fitting. Avoid hammer blows.
(b) Avoid uneven clamping when you lock the unit on the bed.
(b) After the geared motor/reducer has been positioned by means of the spigot
joint of the bracket, tight it firmly.
(c) Connect the output shaft (low-speed shaft) and the driven shaft by means of
a “flexible coupling”.
(d) When radial load and thrust load are applied to geared motor/reducer, install
driven shaft block on the machine in which bearing are fixed to absorb the load
adequately.
Since output shaft (low-speed shaft) and input shaft (high-speed shaft) are
protected with rust preventive coating, remove it with thinner or a similar
Solvent.
2
CONTENT
4.1 Direct Connection
(a) When the input shaft of the driven machine and the output shaft (low-speed
shaft) of the geared motor/reducer are coupled directly, use a “flexible
coupling” and make sure that both ends are in alignment. (Refer to Fig. 1.)
Allowance of
0.05 mm
Dimension A
Allowance of
0.04 mm
Dimension B
Specified by
Dimension X
coupling maker
Make arrangement to ensure that the shaft of driven machine and that of geared
motor/reducer is positioned parallel. When the machine is driven by V-belt or chain,
ensure that the center distance is not too long by setting the proper distance and belt and
chain are stretched at right angle. When the machine is driven by gearing,
geared motor/reducer should be installed setting up the accurate center distance and
avoiding partial bearing of gears, and the output shaft is pushed downward.
When load (overhung load) is applied on the tip of the shaft, it may cause
damage to the shaft. The gearing or chain sprocket wheel must be mounted
such that the point of load application is as near as possible to the face of the
unit to minimize overhung load.
When using chain, it is necessary to give suitable slack to chain. If the tension
of chain is too loose, excessive shock will be generated at starting or load
fluctuations, which may damage both the geared motor/reducer and the driven
machine. Generally, the recommended amount of slack is 2% of span distance.
(Refer to Fig. 2.)
3
CONTENT
L
Fig. 2
(c) Layout of chain driving:
When using chain horizontally for connection with the drive and the driven
machine, arrange shafts so as to give tension to the upper side of chain. Shaft
arrangement of vertical transmission is not recommended, however, if
necessary, the large wheel should be positioned at lower end.
(d) When load (overhung load) is applied on the output shaft, please make sure
that it is within the limit of allowable value. Allowable value of overhung load is
shown in graph of catalogue.
All geared motors are factory-adjusted for maximum voltage if not stipulated
otherwise. Make sure that the voltage on the installation site coincides with that
indicated on the rating plate of the motor. The direction of rotation may be changed
by interchanging two phases of the mains.
The geared motors are connected to the power supply system like any other
three-phase A.C. motors. There are no special instructions for Geared Motors
beyond applicable for standard electric motors. The feed lines should be of sufficient
diameter to avoid any notable drop of voltage upon starting the geared motors.
It is advisable to fit a protective motor switch with adjustable overload relays. This
switch, which is adjusted to the motor rating, cuts out all three phases in case of
overload or failure of one phase. The normal fuses can not give sufficient overload
protection.
4
CONTENT
phase A.C. squirrel cage motors.
5
CONTENT
Viscosity : 30°E at 50°C (abt. 250 cS)
Flash point : +230°C
Pour point : 20°C
Lubricating Table
6
CONTENT
LUBRICATION OIL RECOMMENDATIONS
BRAND GRADE OF OIL GREASE FOR BEARINGS
INTERNATIONAL BRAND
BRITISH PETROLEUM ENERGOL GR-XP 320 OR GR-XP 460 ENERGREASE LS 2
CASTROL ALPHA SP 320 OR ALPHA SP 460 EPL 2
CALTEX MEROPA 320 OR MEROPA 460 STARFAX PREMIUM 2
ESSO PETROLEUM SPARTAN EP 320 OR SPARTAN EP 460 BEACON 2
FUCHS RENOLIN CLP 320 OR RENOLIN CLP 460 FWA 160
MOBIL OIL CO. MOBILGEAR 632 OR MOBILGEAR 634 MOBILUX 2
SHELL CO. OMALA 320 OR OMALA 460 SHELL ALVANIA 2
INDIAN BRANDS
INDIAN OIL SERVOMESH – SP 460 OR SP 320 SERVO GEM – 2
HINDUSTAN PETROLEUM PARTHAN – EP 460 OR EP 320 BEACON 2
CASTROL ALPHA SP 320 OR ALPHA SP 460 EPL 2
GULF EP LUBRICANT 460 OR 320 HD M.P. GREASE 2
BHARAT PETROLEUM AMOCAM 460 OR 320 M.P. GREASE 2
The frequency of inspection and repair should be different according to the operating
condition, however, please conduct inspection and repair with reference to the following
table. (It is based on the operation of 10 hrs/day.)
7
CONTENT
8. TROUBLE SHOOTING
8
CONTENT
TROUBLE SHOOTING OF GEARED MOTOR WITH BRAKE
9
CONTENT
MOTOR MOUNTED TYPE GEAR SPEED REDUCER
INTRODUCTION
Here are some essential procedures for maintenance, inspection and installation.
The motor mount section of this speed reducer is confirmed to the motors of flange
type, three-phase, squirrel cage induction motor for general purpose. Therefore,
please confirm the dimension of motor flange before you fit It, as follows:
1.1 Before mounting the motor, please make sure that the combination of motor
frame number and speed reducer frame number is appropriate.
1.2 Make sure that there is no adhesion of dust on the motor shafts, then set the key
accurately. Please use the key attached to the motor shaft.
1.3 Wipe out the rust-proof paint on the mounting face of motor flange by solvent.
In order to prevent the fretting corrosion or cold seizure at the fitting part of input
hollow shaft of reducer, a special lubricant is already applied on the bore. Do not
clean this lubricant while inserting motor shaft. The bore is covered with suitable plug
to prevent entry of the dust. This plug has to be removed before inserting the motor
shaft.
1.4 Hang the motor horizontally (vertically for type V1), fit the motor shaft in the hollow
shaft. If fitting is not easy, do not force to fit and confirm that the motor is accurately
horizontal. (vertical) Before coupling, please make sure that “Shaft Lub“ is applied to
hollow shaft.
10
CONTENT
2 -STAGE FOOT MOUNTED HELICALGEARED MOTOR
98
CONTENT
11
3 -STAGE FOOT MOUNTED HELICALGEARED MOTOR
98
CONTENT
12
2 -ST GEARED REDUCER
CONTENT
13
3 -ST GEARED REDUCER
CONTENT
14
2 -STAGE AGITATOR HELICAL GEARED MOTOR
98
CONTENT
15
3 -STAGE AGITATOR HELICAL GEARED MOTOR
98
CONTENT
16
2 - STAGE FOOT MOUNTED MOTOR MOUNT HELICAL GEARED REDUCER
CONTENT
99
17
3 - STAGE FOOT MOUNTED MOT OR MOUNT HELICAL GEAR REDUCER
CONTENT
99
18
SPARE PART LIST FOR HELICAL GEARED MOTOR/REDUCER
SR.NO. DESCRIPTION SR. NO. DESCRIPTION
19
CONTENT
OUR MANUFACTURING RANGE
.
Cement, Chemicals, Fertilizers and Steel Industry.
Industrial Magnets
: SELLING AGENT :
EMTICI ENGINEERING LIMITED
REGISTERED OFFICE :
CONTENT
(BOILER – BJ059 & BJ060) DATA SHEET
6.7.11 ELECTRICAL HOIST
DESCRIPTION SPECIFICATION
GENERAL DATA:
MAKE M/s GRIP CRANES & HOISTS
QUANTITY 1 NOS.
CAPACITY 5 TON
KW / HP 3.7 KW / 5.0 HP
TYPE B3
DUTY S4 DUTY
KW / HP 0.26 KW / 0.35 HP
DUTY S4 DUTY
QUANTITY 2 NOS
OPERATIONS
SUPPLIER’S ADDRESS:
M/s. GRIP CRANES & HOISTS,
9 / 1A, 3rd STREET,JAYAPRAKASH
NAGAR,GANAPATHY,COIMBATORE-641002.
CONTENT
CONTENT
INSTRUCTIONS FOR
OPERATION & MAINTENANCE
MANUAL OF
WIRE ROPE ELECTRIC HOIST
Client : M/s. CETHAR VESSELS LIMITED.,
No. 4, Dindigul Road,
Tiruchirapalli – 620 001.
CONTENT
WIRE ROPE ELECTRIC HOIST
INSTALLATION
Electric Hoist is tested under load and adjusted for proper operation before leaving the
factory. Before the unit is placed in service, carry out the following checks and tests.
1. Check the power supply which is indicated on the name plate of hoist. Check the
voltage. Frequency and phase. The voltage supplied to the hoist must be the same
as indicated on the name plate, otherwise over heating of the motor will reduce the
lifting capacity and result in improper functioning of all electrical components.
1. Before mounting the hoist on the rail track, check the distance between the flanges
of the driving wheels and the width of the I-Beam. It is necessary to ensure a
clearance of 5 to 7mm for free movement of the wheels. While checking the
operation of the trolley, ensure that the beam should be cleaned from dust,
lubricants, etc. The distance between flanges can be adjusted by means of
washers placed inside or outside of trolley studs.
2. Refer to the lubrication chart to determine if the hoist is properly lubricated. First
fill of gear box oils is to be done by the consignee before starting.
4. After mounting the hoist on the I-Beam, press the `UP’ push Button, the hook will
start going upward. If the hook lowers instead of going up, two phases of the
terminals should be charged over.
5. Check the operation of the limit switches. Limit switches are set to give minimum
headroom and maximum run out of the wire rope. If required, these limit switches
can be adjusted to give any intermediate height of lift.
6. Test the operation of direct acting electro magnetic brake a few times to determine
if the correct adjustment of the brake is obtained. Ensure that the travel of the
load block stops when the power is cut off. Although, the brake is set before
leaving the factory, it is required, to make slight adjustment to compensate for
initial wear of the lining after 2-3 weeks usage.
CONTENT
GENERAL INSTRUCTIONS TO THE OPERATORS OF ELECTRIC WIRE ROPE
HOIST.
1. Whenever an operator resumes duty, he should examine the unit for its working
order. The brake, limit switches and performance of controls etc. should be invariable
checked up and perfectness ensured.
2. Incase, the above examination and trials reveals some defects which can not be
rectified by the servicing personnel, the operator should write down the
defect/defects. The use of a faulty hoist is by, no means, allowable.
3. The hoist should be positioned in such a manner that the load if lifted perfect vertical
from the start. It should not be positioned to drag the load with the hoisting rope
inclined.
4. While the load is being hoisted, conveyed and lowered no one should put off the load
by hand.
5. No one should move in front of the moving load or in the load failing zone.
LUBRICATION CHART
When an Operator resumes duty the very first thing he has to do is to carry out the daily
inspection procedure. Never use the hoist if it is not in perfect working condition, but,
report the matter to the concerned supervisory staff member or executive.
CONTENT
DURING OPERATION
01. Ensure that the load is vertically below the hoist in case of fixed hoist. If the hoist is
provided with the trolley, bring the trolley just above the load. If the load is much
away from the center, line of the monorail push it manually towards the entire line
until it is placed exactly below the hoist.
02. If the brake is provided for the trolley, traverse the load both ways and test the
performance of the brake. If this brake is also in condition, the hoist is ready for
use. While raising further, check-up the spooling of the rope on the drum and its
smoothness.
03. Avoid impact loading caused by sudden lifting or lowering. Raise the load slowly to
tension the rope gradually and to avoid swing of the load. This can be done by
inching the control before subjecting the hoist to normal / maximum speed. Sudden
hoisting or lowering may cause breakage of wire rope.
04. If the load does not ride properly lower it and have it readjusted.
05. DO NOT lifts the load with excess sling rope hanging loose.
When the hoist is ideal or when the operator leaves the hoist, he has to :
01. Lower off all loads.
02. Raise the hook to its highest position
03. Place all controls in off position.
04. Place main switch off, if any, and lock the switch box.
05. Lock the control / Cab door.
01. CHECK UP that the wire rope is not dry and is not damaged. Lubricate if dry.
02. CHECK UP the lubrication oil level in the gear box, fill up to indicated level, if
required.
03. CHECK UP for loose bolts or studs. DO NOT tighten loose bolts but renew the part
with fresh one.
CONTENT
YEARLY EXAMINATION
01. The load hook should be thoroughly examined for swivel and also for any
distortion, elongation, cracks, etc. If in the opinion of the examiner the hook is to
be discarded, it should be scrapped and replaced. Even if fresh hook is not
readily available the hook should be discarded and the hoist idled until
replacement of hook.
02. The entire structure, mechanism, attachments, chains, ropes, sheaves, drum etc.
should be thoroughly examined for any crack or damages.
03. The gear box should be opened, oil drained out, all gears, pinions shafts, etc.
thoroughly cleaned. Cleaning procedure is laid out under the heating `GEAR
BOX’ MAINTENANCE’. Broken or distorted parts, if any should be replaced.
Bearings should be thoroughly examined. Incase of play between shafts and
bearings replace the appropriate part of bearing or both.
04. BRAKES should be examined for wear and slackness. Any lining or part required
to be renewed should be replaced.
07. FILL UP the gear case with fresh oil as per instructions provided.
GENERAL
This brake works on the solenoid principle. When the solenoid is energized an armature
which is linked with the shoe levers, pulls and pulls the shoe lever apart to release the
brake. When supply is cut off the mechanism comes to the original position under spring
action and brake is applied.
This, the solenoid brake electrically released and spring applied is a fail safe device. The
brake is usually applied to the extended shafts of the motor.
CONTENT
MAINTENANCE INSTRUCTIONS FOR DISC TYPE BRAKE:
GENERAL
Disc brakes are constructed to fit directly on to the non-driving end of motors having
flanges and extended shaft at non-driving end. A driving hub 9normally square) is keyed
and grubbed to the motor’s shaft. Linear plates are fully floating on driving hub. The
brake is spring applied and it is released by electromagnet. The braking torque is easily
adjustable.
ADJUSTMENT OF BRAKE
Adjustment of the required braking torque is done by compressing three main springs
equally by tightening main spring nut. Then adjust air gap (0.5 to 1.0mm max.) with the
help of magnet plate nuts so that gap/gaps are equal all round between magnet body and
armature plate. In any case, air gap should not be more than 1.0mm, if it exceeds, the
coils may burn off.
Connect the incoming supply leads to terminal block and supply current referring the
name plate for proper voltage. Armature plate should be attracted smoothly without any
chattering noise. When supply is ON, motor shaft will be FREE. Then switch OFF the
supply. Repeat `ON & OFF’ two-three times to ensure free movement of armature. If as
armature is attracting immediately after supplying current, reduce spring pressure. After
adjusting the torque, lock the main spring nuts and lock nuts firmly by applying two
spanners simultaneously. Please note `THAT AS SOON AS BRAKE IS SWITCHED ON,
ARMATURE MUST BE ATTRACTED TO MAGNET CLOSING AIR GAP. OTHERWISE, COILS
WILL BURN WITHIN FRACTION OF A MINUTE. After confirming smooth operation of
brake, remove incoming supply leads and connect the brake directly to motors terminal or
as per your requirement.
01. Check up that all the three springs are equally compressed.
02. Air gap is equal all round.
03. All phases are showing the same voltage.
04. Magnet and armature surfaces are clean and no foreign particles are imbedded.
05. If faces of magnet and armature are even, if found uneven after a long use ground
both the surfaces.
CONTENT
BRAKING IS INSUFFICIENT
REVERSING CONTACTORS
Two DOL contactors for each motor are mounted on a base plate complete with electrical
interlock to avoid possibility of both contactors closing at the same time. These
contactors are supplied with 110/2V coils as per customer’s choice.
GRIP Gear box in the Electric Hoist is most reliable seldom right give trouble. This does
not mean that the users need not ascertain the likely caused of eventual troubles. A good
deal depends upon the manner in which the unit has been driven and looked after.
The principal troubles in the fox (Gear Box) which the operator may come across might be
on account of following:-
1. It is of great importance to maintain the required level of the lubricant constant, not
only to prevent the wear but also to maintain silence in operation. The level of the
lubricant should, therefore be periodically examined, especially when it has been used
a good deal.
2. There is a filler plug in every gear box. There is also a level indicator in the form of
tapered screw plug situated within 1/3 to ½ the casing height from its bottom. The
lubricant is to be poured through the filler plug hole (Plug having removed) until it
over-flows through the tapered indicator plug hole (plug having removed).
3. Never fill the gear box with excess of oil. Too much oil will result in definite loss of
power due to churning action and increase in frictional resistance. Too thick oil
should also not be used. The golden rule is to use the recommended gear oil or to
use as thin oil as possible under the circumstances and replenish after maintaining
the required level always.
CONTENT
ROPE INSPECTION – FREQUENCY INSPECTION
For machines in service all running rope should be visually inspected each working day for
distortion, kinking, crushing, unstaring, bird caging main strand displacement, core
protection, loss or rope dia in a short length, narrowing of rope at any portion of its length
of unevenness of strands, general corrosion, broken wire or strands, core failure, etc.
These inspections are for evaluating whether more detailed inspection of the rope or
discarding of the rope is needed.
LOAD TEST
When any rope has been replaced the same has to be tested to rated load and to 25%
overload. The rope obtained be only of known brands and makers Test Certificate should
be obtained against purchase.
CONTENT
COMMON TROUBLES,CAUSES AND REMEDIES IN WIRE ROPE ELECTRIC HOIST
MOTORS / BRAKES
CONTENT
TROUBLES CAUSE REMEDY REMARKS
Poor connection or open Check up and rectify
circuit in stator windings
Creep hoist does not Creep brake disc worn Replace discs or
lift but lowers noisly complete unit
Creep hoist does not Creep motor defective Motor to be changed
function, load slips
down
Creep Hoist does not Main brake not properly Check up the brake
work but is noisy opening levers and set the
brake
Brake does not stop Brake disc in disc brakes Clean the disc or liners
the mechanism quickly are oil socked or thoroughly or replace
(braking time too long) deposited with dirts them
Poor braking action Discs do not make a
good fit.
May have uneven Change the disc or
surface. linings.
May have uneven Reset the brake
contact adjustment until
contact is even.
Brake discs in disc Defective brake Adjust the brake such
brake of linings in adjustments that when released the
shoe brake in good discs just clear each
condition but do not other in disc brake or
stop the mechanism. the shoe linings just
clear off the drum.
Then adjust tension
springs to give the
desired stop.
Stepping of In shoe brake one shoe Adjust the brakes such
mechanism suddenly applies with greater that both the shoes
in one direction forced than the other. clearances are equal
In disc brake, the discs as required. Adjust
are not parallel. the brake. If discs are
worn off unevenly
replace the discs
The brake discs in disc Adjust the clearance
brake or the brake shoes as required.
in shoe brake are
already braking (even if
one shoe brakes heavy
load can not be hoisted)
CONTENT
TROUBLES CAUSE REMEDY REMARKS
Push Buttons gets Push Button section Tighten the housing
stuck shifted screws
Operation Interrupted Loose connection Tighten all connections
chattering or noisy
operation of
contactors
Wire broken Check up wires and
replace if broken
Current collector Check up setting of
contacts too poor shoes and free
movement of arms
Improper sealing of pole Remove dust, oil or
faces and armature other accumulated on
the pole faces and
armature
Contactor coil burning Contactor not closing Check up and replaced
out in the new one.
10
CONTENT
DO NOT:
02. Do not use a hoist designed for a lower class of duty for a higher class, example. do
not use Class II hoist for class III/IV services.
03. Do not use a hoist for any work for which the hoist is not designed.
05. Do not haul the loads on floor with wire rope inclined.
06. Do not allow the hook to be on the ground or hang up to head level.
07. Do not allow impact or shock load on the hoist. In cold regions where the
atmosphere temperature is Zero degree or less the structural parts of hoist may get
brittle and impact or shock load may cause sudden breakage to structure without any
warning.
08. Do not allow swinging of the load during horizontal movement swinging can be
controlled by inching the switch in the initial stage.
09. Do nor use more than one hoist in a common track without ensuring safety against
collusion.
10. Do not use the hoist without ensuring proper operation of the limit switch.
13. Do not keep the hook hanging down when the hoist is not in service.
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11
CONTENT
CONTENT
YET TO RECEIVE FROM VENDOR WILL BE FURNISHED LATER
CONTENT
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