ESP Manual

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Index

CHAPTER -6: ELECTROSTATIC PRECIPITATOR

6.0 TECHNICAL SPECIFICATION

6.1 WORKING PRINCIPLE

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 COMPONENT DESCRIPTION

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
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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 SAFETY PRECAUTIONS

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

6.4.1 GD Test Procedure


6.4.2 Pre-commissioning checkup
6.4.3 Start up
6.4.4 Shut down
6.4.5 Fine Tuning

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 TROUBLE SHOOTING

6.6.1 Introduction

6.7 SUB VENDOR MANUALS & DATA SHEET

6.7.1 Dust level indicator


6.7.2 Transformer Rectifier set
6.7.3 H.T Isolator

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6.7.4 Earth Discharge Rod
6.7.5 Mechanical Safety interlock
6.7.6 Support Insulator Heater
6.7.7 Shaft Insulator Heater
6.7.8 Hopper Heater
6.7.9 Thermostat
6.7.10 Geared Motor
6.7.11 Electrical Hoist
6.7.12 Awaiting Inputs for ESP Package Details are given below:
(a) O&M Manual and G.A Drawing for Transformer Rectifier set
(b) O&M Manual and G.A Drawing Earth Discharge Rod
(c) O&M Manual and G.A Drawing Thermostat
(d) O&M Manual and G.A Drawing Motorised Valve
(e) G.A Drawing H.T Isolator
6.0 TECHNICAL SPECIFICATION

SL.NO. ITEMS UNITS VALUES


A General Information – Boiler
Boiler Type CFBC
Boiler Capacity TPH 495
Steam Pressure Ksc(g) 142
Steam Temperature ºC 540
B General Information - ESP
Manufacturer CVL
Petcoke @ 100%
Fuel For ESP Design
TMCR Condition
Gas Flow m3 / s 213.52
Flue gas temperature ºC 138
Inlet Dust Concentration gm/Nm3 50.35
50 (with one field out
Outlet Dust Concentration mg/Nm3
of service)
Horizontal Flow; Dry
ESP Type
Type
Number of Gas Stream/ESP Nos One
Number of ESP/Boiler Nos 2
Number of Electric Field in Series/ESP Nos 7
Total Active Treatment Length m 31.5
Treatment Time s 50.81
C Collecting Electrodes
Type ‘G’ Profile
Material IS 513 / CRCA
Electrode Thickness mm 1.25
Clear Distance b/w Collecting Electrode
mm 400
Plates
No of Gas Passages / Stream Nos 32
Active Length per Electrode mm 750
Cross Sectional Area of each Passage m2 5.4
Active Height per Electrode mm 13500
254.93 (n fields)
Specific Collecting Area m2 /m3/s
218.51 (n-1 fields)

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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

Total Number of rapping systems/stream Nos 7

Total Number of rapping


Nos 33
hammers/rapping system

Time Interval Between Raps of Same


s Field Adjustable
Rapper
Input Rapping Power to Rapping System KW 0.37
Rapper Controller – Gas Distribution
G
Screen
Type Tumbling Hammer
No. of rapping systems / ESP Nos 1
Total no. of rappers / ESP Nos 16
Time Interval Between Raps of same
s Field Adjustable
Rapper

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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

Creep age Distance mm 490


Maximum Flash Over (Dry) voltage KV 125 (dry)

Location ESP Roof

K High Tension Conductor


Type Bus Duct
Material Copper
Connection Screwed
L Insulator Compartment Electric Heater
Rating KW 1
Control Thermostat
Number of Heaters per Insulator Nos 1
Total Number of Heaters per ESP Nos 28
M Transformer Rectifier Unit
Total Numbers Per Stream Nos 7
Number Per Field Nos One
Mounting Type and Location ESP Outer Roof

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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

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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

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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: -

Electrostatic precipitator is basically an electrical equipment in which the


dust is removed from the flue gas by means of electrical discharge and the
removed dust is collected by means of mechanical rapping system. The
operation of electrostatic precipitator will be of the following four phases

• Ionization of flue gas by high voltage discharge


• Charging of dust particles
• Migration and collecting of dust particles
• Removal of collected dust.

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
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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.

In order to obtain gas ionization it is necessary to exceed, at least locally,


the electrical breakdown strength of the gas. It is called corona discharge.
Sparking is essentially an advanced stage of corona in which complete break
down of the gas occurs. Precipitators are usually operated at the highest
voltage practicable with 5 to 7 sparking, since this increases both the particle
charge and the electrical precipitating field.

Corona discharge is accompanied by a relatively small flow of electric


current. Sparking usually involves a considerably larger flow of current, which
cannot be tolerated except for occasional periods of a fraction of a second
duration, and then only when suitable electrical controls are provided to limit the
current. However, when suitable controls are provided, precipitators have been
operated continuously with a small amount of sparking to ensure that the voltage
is in the correct range to ensure corona. Besides disruptive effects on the
electrical equipments and electrodes, sparking will result in low collection
efficiency because of reduction in applied voltage, re-dispersion of collected dust,
and current channeling.

6.1.4 ADVANTAGES OF ESP: -

Electrostatic precipitators have gained its popularity over other dust


collecting equipments because of the following advantages.
• Low pressure drop
• Higher collection efficiency
• Less sensitive for temperature variations
• Suitable for any type of dust
• Lower maintenance and runtime cost

6.1.5 PARAMETERS AFFECTING ESP PERFORMANCE: -

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.

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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

6.1.5.1 RESISTIVITY OF DUST PARTICLE: -

Resistivity is an electrical characteristic based on which the charging


capacity of a dust particle at the given charging condition can be determined.
Resistivity depends on the composition and morphology of the dust particles.

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.

The low resistivity dust creates the problem of re-entrainment. If the


resistivity of dust is very low then the particles will discharge rapidly as soon as
collected over the collecting panels. Hence they are nowhere electrostatically
pinned with collecting electrodes and can be easily swept along with flue gas.
Sometimes the particles will acquire positive charge from the collecting panel and
get repelled. The problem of low resistivity mainly occurs with precipitators
operating at low temperatures and handling ash from high sulphur coal.

6.1.5.2 FLUE GAS TEMPERATURE AT ESP INLET: -

The variation of resistivity of flue gas with temperature doesn’t have a


greater impact on the performance of ESP, if the variation is minor. On the other
hand the viscosity of flue gas increases with increasing temperature that imparts
more drag on dust particles. The performance of electrostatic precipitator is
highly influenced by increase in flue gas temperature. The rise in temperature will
decrease the electrical property of flue gas i.e., the resistivity of flue gas will
increase with increasing temperature. This high resistivity of dust will lead to

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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 strength of the mechanical components, especially insulators will be


reduced when the ESP is operated at a higher temperature than the designed
value or if there is frequent variation of flue gas temperature over a wide range.

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.

6.1.5.3 FLUE GAS VOLUME FLOW RATE THROUGH 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.

6.1.5.4 FLUE GAS COMPOSITION:-

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

6.1.5.5 PERCENTAGE OF MOISTURE IN FLUE GAS:-

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

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maximum increase of 5% of moisture in flue gas can improve the performance of
ESP to certain limit.

6.1.5.6 PERCENTAGE OF SULPHUR OXIDES IN FLUE GAS:-

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.

6.1.5.7 PERCENTAGE OF OXIDES OF SALTS IN FLUE GAS:-

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.

6.1.5.8 PERCENTAGE OF ALKALI METALS IN FLUE GAS:-

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.

6.1.5.9 FLUE GAS VELOCITY WITHIN ESP: -

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.

6.1.5.10 INLET DUST CONCENTRATION: -

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.

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6.1.5.11 OUTLET DUST CONCENTRATION: -

Outlet dust concentration is an important parameter for dust collection


systems. It depends on pollution control norms. It will decide the overall
performance of the dust collection systems .hence if there is any variation in the
boiler parameters it will affect the emission level. The outlet emission will increase
with respect to increasing inlet dust load for a given ESP.

6.1.5.12 GAS DISTRIBUTION INSIDE ESP:-

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.

6.1.5.13 RAPPING FREQUENCY:-

The collected dust particles are to be removed in certain intervals by


means of rapping mechanisms. The rapping frequency should be set with
respect to the type and amount of dust collected in the precipitator. Higher
rapping frequency will lead to re-entrainment of dust particles into the flue gas
stream. Lower rapping frequency will lead to accumulation of thick layer of dust
over the collecting plates thereby increasing the sparking between electrodes.
The lower rapping frequency will also lead to heavy puffing of dust by re-
entrainment while rapping. Hence a dust layer of sufficient thickness should be
allowed to form so that while rapping the layer breaks into agglomerate masses,
sufficiently large to fall into hopper before being carried forward by the gas
stream. The rapping frequency can be individually controlled for each field based
on the dust laden to the field.

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CONTENT
6.2 COMPONENT DESCRIPTION

6.2.1 INTRODUCTION: -

The success of any system depends on proper design, selection of material


and method for construction and also the design of associated systems. This
section has been developed to provide a general idea about the constructional
features of CVL ESPs. The knowledge about the various components involved in
a system will help the end user to know the system in detail and operate it in a
more efficient way. This helps in sorting out the possible failure of system during
operation and also easy for maintenance.

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.

6.2.2 COLLECTING ELECTRODES:-

The collecting electrodes are 750 mm wide selected as per design


requirement. It is of 1.25 mm thick mild steel sheet made by cold rolling process.
The profile of collecting electrodes is aerodynamically designed for higher
stiffness and to minimize re-entrainment of dust particles along with the moving
flue gas. The collecting electrodes are also designed to reduce sparks to sharp
edges. The collecting electrode curtains are hung from support angles connected
to ESP roof beam. The bottom of collecting electrodes are connected together
and made as a panel by means of shock bars at the end of which the shock bar
pads are bolted.

6.2.3 EMITTING ELECTRODES:-

The emitting electrode is a spiral wire made of high-alloyed stainless steel


material. The electrodes are supplied to site as closely wound coils. During
erection the electrodes have to be stretched using stretching device
adequately/uniformly and connected between suspension frames. These spiral
electrodes are self-tensioned and remain in its position perfectly aligned. Further
these electrodes are easy to handle, install and to maintain. Moreover they
produce a uniform current distribution over the entire height of the collecting
electrode panels.

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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.

6.2.5 TR SET WITH CONTROLLER:-

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.

• During no sparking conditions, maximum power is made available across


the ESP.

• 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

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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.

6.2.7 MECHANICAL SAFETY INTERLOCK SYSTEM:-

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.

6.2.8 HOPPER HEATERS:-

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.

6.2.9 HIGH LEVEL SWITCHES IN HOPPER:-

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.

6.2.10 ESP CASING, HOPPERS, INLET AND OUTLET FUNNELS:-

Casing plays the important role in the construction of precipitator. It is


made out of rigid welded construction consisting of prefabricated columns, side
and roof panels. The casing construction itself requires much higher time during
erection. The casing has been designed for various loads and proper selection of
column and stiffener members have been done to provide a rigid construction.
The casing panels are fabricated either at shop floor or at site to closer

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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.

6.2.11 COLLECTING ELECTRODE SUSPENSION:-

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.

6.2.12 COLLECTING ELECTRODE RAPPING:-

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.

6.2.13 EMITTING ELECTRODE SUSPENSION:-

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.

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6.2.14 EMITTING ELECTRODE RAPPING:-

Tumbling hammers, which are mounted, on horizontal shafts supported in


the frame itself, does rapping of discharge electrodes. The hammers hit the
special shock beams, to which the intermediate frames are connected. Due to
rigid framework the rapping energy generated by the hammers is distributed
efficiently to all parts of the framework, including all the discharge electrodes.
The rapping shaft is directly coupled to drive unit via shaft insulator housed in an
insulated box. Coil type heater is provided to heat shaft insulator in order to avoid
clogging of dust.

6.2.15 GAS DISTRIBUTION SCREEN ARRANGEMENT:-

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.

6.2.16 ELECTRICAL HOIST:-

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:-

 Improved reeving arrangement to minimize rope twisting, hence longer life


of rope
 Emergency off pushbutton is provided as standard feature to avoid any
mishap if any contactors's contact get welded or limit switch fails to
operate.
 Gear box completely sealed to avoid any drippage of oil.
 CT gear box are of cast steel and not of cast iron .

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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.

O & M MANUAL FOR ESP

CONTENT
6.3 SAFETY PRECAUTIONS

6.3.1 INTRODUCTION:-

Operation of the precipitator involves the application of very high voltages.


Safety services have been provided to reduce this risk and other possible
hazards. Only persons fully trained in the operation and maintenance of the
precipitator shall access to the precipitator power supplies. The following
systems are provided for human safety and it has to be used to avoid the risk of
electrical hazards.

6.3.2 MECHANICAL KEY INTERLOCK SYSTEM:-

This interlock system is a sequential key arrangement that prohibits


operation of any precipitator gas path unless its access doors are closed and
locked. This also ensures that the access doors can be opened for maintenance
or for any purpose only after the grounding switch is set to the ground position.
The key interlock system also makes it impossible to accidentally enter an
energized precipitator.

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.

6.3.3 DISCHARGE ROD:-

Each casing is provided with 2 Nos of discharge rods. These discharge


rods consist of an insulator handle with steel tipped hook. A flexible braided wire
is connected to the steel tips and the other end of the strap is securely grounded
to the precipitator structure. All the HV components are to be grounded with
discharge rod before any personnel get entered into the precipitator. Regularly
check the discharge rods for proper grounding and for breakage.

6.3.4 DOs AND DON’Ts: -


DOs

1. Use discharge rod whenever entering the precipitator.

O & M MANUAL FOR ESP

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. Never violate established plant clearance practices


2. Never bypass the safety key interlock system.
3. Never open a hopper door unless the dust level is positively below the door.
Check from the upper access in the precipitator to ensure ash level and do
not trust on dust level indicators always.
4. Ozone is created while energizing and hence do not enter the precipitator,
duct or stack without suitable mask to avoid ozone inhalation.
5. Never touch exposed internal parts of control system.
6. Never use fingers or metal screwdrivers to adjust uninsulated control devices.

6.3.5 FIRE EXPLOSION: -

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.

O & M MANUAL FOR ESP

CONTENT
6.4 COMMISSIONING

6.4.1 GD TEST PROCEDURE:-

The gas distribution test is an important pre-commissioning activity and is


conducted to verify and achieve uniform flow distribution across the cross section
inside the electrostatic precipitator.

While designing the electrostatic precipitators of high collection efficiency, one


of the factors considered by the designer is to achieve the uniform gas distribution
across section of precipitator so as to ensure the effective utilization of the
collection area provided in the precipitator.

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 velocity measurement is made inside the precipitator chamber between


the first field and second field.

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.

O & M MANUAL FOR ESP

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.

• If the flow is to be deflected downward direction, deflection plates are


fixed in the rear side of the GD Screens.

• If the flow is to be deflected upward direction, deflection plates are fixed


in the front side of the GD Screens.

• If the flow is to be deflected upward direction and downward direction,


throttling plates are fixed in the front side of the GD Screens

• Plates are fixed both in the primary & secondary screens depending upon the
requirement.

6.4.2 PRE – COMMISSIONING CHECKUP:-

1. All bearing temporary (locking) arrestors are to be removed.


2. Check oil level in all the rapping geared motors.
3. Check direction of rotation of all rappers and angular displacement of
hammers
4. Check all the hammers are free to move and all the fasteners are sufficiently
tight and welded.
5. Check the proper functioning of rappers in ‘Manual’ mode and in ‘Auto’ mode
through the rapping programmer.
6. Check the healthiness of all insulator heaters and set the thermostat for
required temperature. Check the control of heaters by thermostats.
7. Check the healthiness of all hopper heaters and set the thermostat for
required temperature. Check the control of heaters by thermostats.
8. Check that the dust level indicators are in proper working condition.
9. Check the interlock circuit of dust level indicator with the transformer rectifier
control panel.
10. Check the proper functioning of panel instruments related to ESP operation.
11. Carry out a complete checking of entire precipitator field for any tools, welding
rods, metal parts and any other foreign material.
12. Close all the access doors with airtight sealing and in accordance with the
safety interlock system.

O & M MANUAL FOR ESP

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.

6.4.3 START UP:-

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).

6.4.4 SHUT DOWN:-

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.

O & M MANUAL FOR ESP

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.

O & M MANUAL FOR ESP

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.

The precipitator has to be maintained in the following important areas

• Gas distribution
• Voltage distance
• Dust deposits
• Periodic Ash Evacuation of hoppers

6.5.2 MAINTENANCE OF GAS DISTRIBUTION:-

In general before commissioning of ESP gas distribution test will be carried


out for uniform gas distribution over the entire cross section of precipitator. It has
been achieved by placing some of deflector plates on gas distribution screens.
This uniform gas distribution has to be maintained over the entire life of ESP to
achieve the expected performance. The performance of precipitator will
deteriorate if this gas distribution is affected or disturbed. After 5 to 7 years of
operation, GD Test must be repeated, keeping the deflection plate on the GD
Screens replaced afresh as they would have been eroded by then.

6.5.3 MAINTENANCE OF VOLTAGE DISTANCE:-

The discharge electrode system should be symmetrically located with


respect to the collecting electrode system. Misalignment between these systems
will reduce the voltage distance and hence reduce the operating voltage.

6.5.4 MAINTENANCE OF DUST DEPOSITS:-

The deposits on various precipitator zones will affect the performance to


greater extent. The dust accumulation on inlet gas distribution screen will destroy
the gas distribution inside precipitator and the deposition of dust on discharge and
collecting electrode will reduce voltage spacing and hence reduce the operating
voltage of the precipitator. Dust accumulation in other areas like inlet duct and
outlet duct may also lead to improper distribution of flue gas inside the
precipitator.

O & M MANUAL FOR ESP

CONTENT
6.5.5 IMPORTANCE OF ASH EVACUATION FROM HOPPERS:-

6.5.5.1 PHENOMENA OF ASH COLLECTION:-

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.

In the precipitator , the collecting electrode collects maximum quantity of dust.


The dust will be depositing on collecting electrode and are allowed to form like a
cake. The deposited dust must be periodically removed from collecting / Emitting
electrodes so as to sustain the corona discharge and the process of precipitation.

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.

6.5.5.2 IMPORTANCE OF ASH EVACUATION:-

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.

O & M MANUAL FOR ESP

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.

O & M MANUAL FOR ESP

CONTENT
6.6 TROUBLE SHOOTING

6.6.1 Introduction:-

Electrostatic Precipitator is mainly constructed out of static equipments and


few moving parts in rapping systems. However, the ESP internals are operated
at a high loading and dirty environment under relatively high and unfavorable
temperature conditions.

Any defects in the precipitator will lead to insufficient operation and a


deteriorated performance or even complete shutdown of ESP.

The following major systems have to be checked during trouble shooting of


ESP.

• Electrical power supply system


• Electrode cleaning system
• Insulator compartments
• Inlet and outlet funnels
• Inlet GD system
• Emitting electrode system
• Collecting electrode system
• Hoppers
• Structural steels and sliding bearings
• Thermal insulation
• Dust characteristics

Typical mechanical and electrical failures, their possible reasons and


recommendations to overcome the failure in the above-mentioned systems have
been tabulated.

O & M MANUAL FOR ESP

CONTENT
SL. RECOMMENDED REMEDIAL
TYPE OF FAILURE REASON FOR FAILURE
NO. ACTION

Thermal stresses. Uneven Clean and grind the support


surface of top and bottom flange and ensure that rubber
support flange gaskets are installed

Crack due to leakage


current on the inner surface Clean the insulator inner
Mechanical cracks in
of insulator due to surfaces, if required replace
01 high voltage support
conductive layer, dust or the insulator. Check the
insulator
condensate(creepage healthy condition of heaters
distance becoming lesser).

Total failure of insulator due Replace the insulator. Check


heavy leakage current the healthy condition of
through dust or condensate heaters

Water leakage into bus


Dry insulator. Check the bus
Mechanical crack in duct b/w TRSET & support
duct for water leakage and
02 high voltage bushing insulator compartment
tighten all the flanges with rain
insulator wetting the insulator giving
guards and asbestos rope.
leakage current.

Crack due to leakage


current on the inner surface
of insulator due to Clean the insulator. Check the
conductive layer, dust or healthy condition of heaters.
condensate(creepage
Mechanical crack in distance becoming lesser).
03
shaft insulator heaters
Crack due to any Check the shaft is in tact and
misalignment of shaft with in line with the insulator.
the insulator causing Check whether the shaft is
uneven loading of insulator. rotating freely.

O & M MANUAL FOR ESP

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.

Check that the rapping


hammers are properly hitting
the shock bar pads. Check
Dust build up on
the hammer bolts are in full
05 collecting electrode Improper rapping
tight. Check the driving
panels
coupling. Check the rapping
frequency and adjust to a
suitable value.

Check the dust deposits on the


GD screens and the reason for
Swinging collecting
06 Improper gas distribution that. Huge dust build up in
electrodes
screens will result in improper
distribution

Failure of one or two shock bar


pads can be repaired
Fatigue failure due to temporarily. If the ESP had
07 Shock bar pad failure
continuous running worked for a long period total
replacement of shock bar pads
is recommended

O & M MANUAL FOR ESP

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.

Leakage due to worn out Replace the worn out gaskets


Air-in leakage through
09 gaskets or improperly and close the doors airtight
access doors
closed inspection doors after completion of works.

Air leakage in to the


Check the insulator doors are
compartments. Support
Condensation of ash sealed properly. Clean the
10 insulator heaters are not
on support insulators insulators. Check the healthy
working or set at lower
condition of heaters.
operating temperature.

Mechanical failure of
11 It is rare to happen. Replace the electrode
emitting electrodes

Excessive accumulation of Increase the rapping


12 Back corona effect high resistive ash over frequency and operate with
collecting surface higher Charge Ratio.

Clean and dry insulators.


Low operating temperature Check the proper function of
Condensation of ash of flue gas. Moisture insulator heaters. ESP should
13
over insulators gathered during shutdown not be operated at
or low load operations. temperature less than dew
point.

Sticking of dust over Maintain the temperature


Acid dew point temperature
14 electrodes and difficult inside ESP greater than acid
will be low
to dislodge dew point temperature

O & M MANUAL FOR ESP

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.

By passing of flue gas Provide necessary baffle


16 through ESP inactive Improper gas distribution plates to divert the flow into
zones active zone

Inadequate thermal Check for proper function of


insulation or heating of hopper heaters. Provide
Plugging of ash
17 hoppers. Malfunctioning of sufficient insulation thickness.
hoppers
ash conveying systems. Check for proper function of
ash conveying system.

The rapping frequency may


not be sufficient or the
Check the proper working of
Heavy re-entrainment rapping system is not
rapping system. Adjust the
18 of dust particles during properly functioning. If the
rapping frequency based on
rapping rapping frequency is much
dust loading.
higher it will also lead to re-
entrainment.

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

Short circuit in the system


T/ R set readings
after TR. Check for ground
No primary voltage
in bus duct, insulator
Normal primary current Take necessary action based
20 housing or in esp casing,
Normal secondary on type of failure
full hopper, broken
current
discharge electrode, broken
No secondary voltage
support insulator.

O & M MANUAL FOR ESP

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

Control circuit mis-


Unstable voltage and adjustment or
24
current malfunctioning. Shorted
surge protector

Broken or slack discharge


electrode, unstable
Heavy fluctuation in
25 discharge electrode system
voltage and current
or dust buildup on
discharge electrodes

High voltage than


Dust buildup in emitting
normal
electrodes, high resistive
26 Low current
dust or higher dust loading,
Sparking or non
un-connected bus section
sparking condition

Gradual voltage drop


Coating of dust on emitting
27 with steady current
electrodes
and sparking

O & M MANUAL FOR ESP

CONTENT
Gradual voltage drop Tracking insulators, hopper
28
with increasing current jamming

Plugged hopper, shorted


Abnormally low or no
29 insulator, broken discharge
voltage. High current
electrode

Higher spark rate in


30 Ambient air in leakage
one chamber only

Cracked HV support
Low secondary voltage
insulator, close internal
31 Low secondary current
electrical clearance,
Sparking condition
Controller problem

Low secondary voltage


32 Low secondary current Controller problem
Non sparking condition

Excessive emission Adjust the rapping frequency


Frequent or inadequate
while precipitator to required level. Check the
33 rapping, more flue gas flow
operation at maximum flue gas flow rate and inlet
than designed
power dust loading.

Short circuiting or low


34 Heater failure Replace the failed heaters
resistance to ground

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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.

Dust buildup in flue gas


Increasing system
36 inlet passage or in inlet gas Clear the flue gas passage
pressure drop
distribution screens

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

O & M MANUAL FOR ESP

CONTENT
6.7 SUB VENDORS MANUAL & DATA SHEETS

(BOILER – BJ059 & BJ060) DATA SHEET


6.7.1 DUST LEVEL INDICATOR
DESCRIPTION SPECIFICATION
GENERAL DATA
MAKE M/S. EIP BULK CONTROLS PVT. LTD.

QUANTITY 28 NOS.

APPLICATION TO MEASURE FLY ASH LEVEL IN ESP HOPPER

TYPE RF TYPE

MODEL RF – 550

INDICATOR DIGITAL

COMPONENT 1. ELECTRONIC CONTROLLER

2. SENSING PROBE HEAD

3. COAXIAL CABLE TO CONNECT ELECTRONIC

UNIT & SENSING PROBE (10m APPROX)

PROBE
MODEL RF-550 RT CB

MOUNTING ESP HOPPER (3/4 BSP MOUNTING)

VESSEL TEMPERATURE 220°C

INSERTION LENGTH 220 MM

ELECTRONIC UNIT
MODEL RF-550 RT EC

TYPE SOLID STATE

SUPPLY VOLTAGE 110V ± 10%, 50 Hz AC

OUTPUT DPDT RELAY O/P 5A @ 230V AC

AMBIENT TEMPERATURE 10 °C TO 60°C AT 100% R.H

SUPPLIER’S ADDRESS:
M/S EIP ENVIRO LEVEL CONTROLS PVT.LTD.
B-130, SECTOR-X,NOIDA - 201301,UTTAR PRADESH.

(BOILER – BJ059 & BJ060) DATA SHEET

O & M MANUAL FOR ESP

CONTENT
INSTALLATION OPERATION
&
MAINTENANCE MANUAL

RF LEVEL SWITCH
MODEL : 550

EIP ENVIRO LEVEL CONTROLS PVT LTD


NOIDA - INDIA

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 Level Switch comprises of an Electronic Controller, a Sensing Probe &


Co-axial Cable for the connection of the Electronic Controller to the probe.
Controller provides RF signals to the probe and measures the changes in
parameters provided by the sensing probe mounted in the material (to be
measured) container. The Sensing Probe do not contain any electronics.

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.

Drawings of electronic unit, sensing probe and electrostatic protector with


connection details are included in this manual in Section V.

3
CONTENT
B. EQUIPMENT SPECIFICATION

1. ELECTRONIC CONTROLLER – MODEL - 550


♦ Line Voltage 220 /110/24 VAC OR DC OR as specified
Line Voltage Sensitivity ± 10%
♦ Frequency Hz 50 / 60 ± 10% for AC Supply
♦ Power Consumption 3 VA Approx.
♦ Ambient Temperature Limits (-) 10 to (+)60oC. or as specified
♦ Output Relay 2 sets of Change over potential free contacts
(SPDT) or as specified.
♦ Contact Rating 5 AMPS 220 VAC non-inductive or as specified
♦ Local LED Indications
Green Normal Level
Red Alarm Level
Yellow Probe Healthy : LED glows off in the case of
Probe or probe cable short circuited to ground
or supply off. It is not effected by loose open
probe cable connection i.e. yellow LED
continues to glow viz.
Probe / Cable proper connection must be
ensured.
♦ Cable length, Electronic unit 25 Mtrs (max.) unless confirmed by EIP.
to probe, Special cable
supplied by EIP only.

2. SENSING PROBE

Model PR-550 RT ST / PR-550 HT PR-550


ESP / BE/ FLX FLSH
♦ Ambient Temp. 250oC (Max.) 600 oC 260oC
♦ Vessel Pressure Customer Specification ___________________________
♦ Probe Type _______Rigid or Flexible ___________________Flush / DISC
Material Construction
Exposed Metal SS 304 SS 316 SS-304
Insulation PTFE Ceramic PTFE
Insertion Length 50 to 10000 50 to 7000 Zero
mm
♦ Mounting 40 / 20NB BSP threaded or flanged Flanged

Note : For other special requirements contact EIP ENVIRO.

4
CONTENT
3. PROBE HEAD
For use with SWITCH Model Probes

♦ Construction Cast Aluminum


♦ Connection Sizes Probe 1½” BSP
♦ Conduit / Cable Gland connection : ½” BSP
♦ Size : Ref drawing in section V

4. ELECTROSTATIC PROTECTOR

♦ Mounting Provided inside the Probe Head

5. CABLE-Model SWITCH -226


For connection of Probe and Electronic Controller

♦ CABLE Special coaxial cable, connection


Centerwire for Probe connection,
Middle shield for Signal
connection, Top layer wire for
Ground Connection
♦ Conductor Copper
♦ Insulation PVC/PTFE

5
CONTENT
II. INSTALLATION

A. RECEIVING & INSPECTION

‘To ensure proper receipt of material, it is important to immediately check


the content of shipping containers. Contents should be compared against
packing list to ensure proper equipments have received and that it has not
been damaged during transit. If any discrepancies arise, consult EIP factory.

B. ELECTRONIC CONTROLLER

1. UNIT LOCATION

The following should be considered while mounting the electronic controller :

♦ Location Mount on convenient structure (near to


probe location) free from obstruction, at
man height for easy operation.
♦ Temperature Be sure ambient temperature at
installation point does not exceed unit
temperature limitation, (-) 10 to (+)
60oC.
♦ Environment Install unit at a location so that no
exposure to direct sunlight, rain or
snow
♦ Vibration If excess vibration in the area is
anticipated, consider alternate
mounting area or place vibration
absorbing material under enclosure
base.
♦ Distance Be certain cable distance from probe to
electronic controller is minimum
possible and does not exceed 25 mtrs.
maximum.
(For longer cable length confirm with
EIP)

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)

1. LOCATION & INSTALLATION

The following should be considered while mounting sensing probes.


i. Verify that material will cover the active section of the probe at the proposed
mounting location consider the probe length.
ii. Be certain that shield section of the probe must project freely inside the
vessel (at least 1” or 25 mm) for Rod type/flexible probes.
iii. Be certain there is a sufficient clearance outside the hopper for inserting and
wiring. For thermal insulated vessel use lagging extension (of length equal
to thickness of insulation) for easy access to terminals.
iv. Disc type (flush mounted) probe must be either flushed with inner surface of
hopper wall or may project inside (up to 5mm) but not remain behind the
inner surface of the vessel.
v. Probe must be almost perpendicular (90 + 15o) to the vessel wall on which
probe is mounted, unless confirmed by EIP.
vi. Active section must not be too close to any other grounded metal part/of the
hopper/Vessel maximum possible gap must be maintained. Preferable
location along centre line of the wall/plate of the vessel.
vii. Termination must be done with proper lugs & gland and each conductor
must be totally isolated from each other.
viii. Flexible/Probe length is selected considering angle of response (for solids),
roof thickness, mounting nozzle height etc. As rule of thumb for solid
materials, horizontal distance from fill point/points must be less than the
insertion length of the probe.
ix. Select location for flexible top mounted sensing probe nearest (possible) to
the vertical center axis of the filling point/points & maximum possible
distance from side walls.
x. Probe grounding of Hopper/Vessel body with electronic controller must be
ensured
xi. Do not provide additional metallic protection like pipe/channel/plate inside
the vessel covering the sensing probe, if provided must be removed, as this
can result malfunctioning. For large size particles (side mounting), use disc
type flush mounted model SWITCH-FP probes.
xii. Coaxial cable supplied/specified by EIP only to be used for the connection
of sensing probe to electronic unit.
For and additional queries contact EIP application engineering staff, if required.

7
CONTENT
D. ELECTROSTATIC CHARGE PROTECTOR

Electro-static charge protector is provided on all applications where the possibility


of electrostatic charge build up on the probe exist. This protector, a small board
is mounted inside the Probe Head. It fastens directly to the active section of the
probe via screw connections. The probe cables from the electronic unit are
fastened to Terminal connections on this board.

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

Before start-up ensure that all the following must comply.

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.

1. Ensure the level of application material well below the probe.

2. If time delay opted, select “Cal/Opn” switch to “Cal”

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.

3. Turn further cw turns to preload the setting.


4. Increase the material level above the desired level of operation and check
the unit operation, the local indication LED glows “RED”/
5. If unit does not respond, the preload setting must be reduced.
6. Verify once again with material level for satisfaction of calibration.
7. If time delay opted select “Cal/Opn: switch to “Opn”.

CALIBRATION IS NOW COMPLETE

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

Verify supply voltage at supply terminals, if it is as it should be Yellow LED and


one of Red or Green LED glows, if not, check Fuse (rating 100 mA)
a. Disconnect the probe cable connections (centre wire, shield wire, ground
wire,) at the electronic unit. Leave (specified) power connected.
b. Hold two Screw Drivers in your hands from non conductive portion.
c. Touch the Screwdriver G and PR terminals (Probe Connection) at the
Electronic Controller.
d. Touch the metallic portion of the screw drivers by fingers. Proceed to B1e
(below).
e. If the relay actuates and de-actuates on disconnecting the screw driver from
the terminal PR and again actuates by replacing the screw drivers at terminal
PR, the Electronic Controller is working properly. Proceed to section IV B-2
checking the Probe.
f. With probe cable connection disconnected at electronic unit, a Volt-ohm
meter (VOM) which is set on low DC Voltage range (20 VDC) Proceed to g.
g. With specified input power applied to the electronic unit, measure the
following voltage on the unit terminals.
i) Probe to ground ………………………….. VDC
ii) Shield to ground …………………………..VDC

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

a. Reconnect coaxial cable (Probe Cable) to electronic unit.


b. Repeat IV B1 f & g corresponding with material level below probe.
i) Probe to ground ………………………….. VDC
ii) Shield to ground ………………………….. VDC
Both should read with in 20% of the values obtained in IV 1g
c. If possible, repeat IV B1 f&g corresponding with material level above 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

a. Disconnect Probe cable at both probe and electronic unit.’


b. Using VOM on the resistance scale measure the resistance between centre
wire (CW) and middle layer (MW) of the cable end at the electronic unit. This
reading should be infinite “open circuit”.
c. If infinite in b, short CW and MW at probe end of the cable using a short
jumper measure resistance between CW and MW at electronic unit end of
cable. This reading should be zero, (Short-Circuit)
d. Repeat step b and c measuring between MW and ground wire (DW) Reading
should be as above.
e. If reading are correct, confirming continuity and no shorting of the cable the
probe cable is in proper condition.
f. If reading are incorrect, check cable for loose or broken terminations or
shorting. If none can be found, the cable should be replaced.

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.

EIP ENVIRO LEVEL CONTROLS PVT LTD


B-130, SECTOR-X,
NOIDA – 201 301 (U.P.) INDIA.
TEL. : 0120-2442527 & 2442528
FAX . : 0120-2555767
Email : eipindia@vsnl.net.in

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.

O & M MANUAL FOR ESP

CONTENT
(BOILER – BJ059 & BJ060) DATA SHEET

6.7.3 H.T. MANUAL ISOLATOR

DESCRIPTION SPECIFICATION

GENERAL DATA:

MAKE M/S. ASSOCIATED POWERCON

QUANTITY 14 NOS.

APPLICATION SAFETY DEVICE FOR ESP

MODEL NO. STYLE I = 7 NO., STYLE II = 7 NOS.

ENCLOSURE FABRICATED SHEET STEEL

PROTECTION GASKET FOR DUST & WATER PROTECTION

PAINTING LIGHT GREY SYNTHETIC PAINT

CONTACTS I) FIXED LINE CONTACT FOR CONNECTING WITH

FIELD TR SET.

II) FIXED EARTH CONTACT FOR EARTHING FIELD

SIDE.

III) MOVING KNIFE WITH ROTARY INSULATOR

COLUMN TO CONNECT FIELD SIDE EITHER

WITH TR SET OR WITH EARTH.

ISOLATOR BLOCK PROVIDED

HANDLE MANUAL

SUPPLIER’S ADDRESS:
M/s. ASSOCIATED POWERCONEQUIPMENT (INDIA) PVT LTD,
7,ELECTRONIC ESTATE ,
PUNE – SATARA ROAD,
PUNE-411 009.

O & M MANUAL FOR ESP

CONTENT
/// POWERCON PAGE 1 OF 17

PROJECT : HT DISCONNECTOR SWITCH FOR STYLE 1

CUSTOMER : CETHER VESSELS PVT LTD.

CONTENT
/// POWERCON PAGE 2 OF 17

/// ASSOCIATED POWERCON EQUIPMENT ( I.) PVT. LTD.


GAT N. 105, VILLAGE RANJHE, TAL- BHOR,
PUNE – 412 205.

OPERATION & MAINTENANCE MANUAL

HT DISCONNECTOR SWITCH FOR HIGH VOLTAGE RECTIFIER POWER SUPPLY FOR


ELECTROSTATIC PRECIPITATOR.

CONTENT
/// POWERCON PAGE 3 OF 17

HT DISCONNECTOR SWITCH FOR STYLE-1

CONTENT
/// POWERCON PAGE 4 OF 17

CONTENTS

ATTENTION

IMPORTANT INSTRUCTIONS

INTRODUCTION

DESCRIPTION OF TOTAL OPERATION

DRAWINGS AND SPARE PARTS LIST

CONTENT
/// POWERCON PAGE 5 OF 17

ATTENTION

These instructions are to be followed when the equipment is received at site.

 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.

 In case of physical damage in transit displacement of parts, missing components


necessary prompt and urgent action should be taken, and this should be reported to the
concerned authorities.

 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.

7.Routine maintenance instructions should be strictly adhered to.

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 .

1. Thermal Power Plant De- dusting of exhaust gases from


boilers.
2. Paper Industry De- dusting of exhaust gases from
boilers.
3. Cement Plant Dust precipitation from air or waste
gases dryers & crushers , rotary kilns
etc.
4. Coal Industry Dust precipitation in steam and gas
heated coal dryers.
5. Chemical & Fertilizer plants. Demisting of gases.
6. Industrial air conditioned Air cleaning.
installations.
7. Paint Industry Separating metal oxides, pigments.
8. Iron and steel Industry De- dusting of waste gases from
blast furnaces.

CONTENT
/// POWERCON PAGE 8 OF 17

DESCRIPTION OF TOTAL OPERATION

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

INTERNAL CONNECTION OF HT SWITCH

CONTENT
/// POWERCON PAGE 10 OF 17

HT DISCONNECT SWITCH SIDE VIEW

CONTENT
/// POWERCON PAGE 11 OF 17

HT DISCONNECT SWITCH

2
1

1) TR SET TERMINAL IS CONNECTED TO FIXED INSULATOR-1


2) FIELD TERMINAL IS CONNECTED TO FIXED INSULATOR-2

CONTENT
/// POWERCON PAGE 12 OF 17

INTERNAL STRUCTURE OF HT SWTICH

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

EARTH SWITCH POSSITION WHEN FIELD CONNECTION TO TRSET

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

EARTH SWITCH POSSITION WHEN FIELD CONNECTION TO EARTH

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

FIELD CONNECTION TO EARTH

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

FIELD CONNECTION TO TRSET

1) FIELD CONNECTED TO TR SET

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 CONNECTION PLATE

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

PROJECT : HT DISCONNECTOR SWITCH FOR STYLE 2

CUSTOMER : CETHER VESSELS PVT LTD.

CONTENT
/// POWERCON PAGE 2 OF 17

/// ASSOCIATED POWERCON EQUIPMENT ( I.) PVT. LTD.


GAT N. 105, VILLAGE RANJHE, TAL- BHOR,
PUNE – 412 205.

OPERATION & MAINTENANCE MANUAL

HT DISCONNECTOR SWITCH FOR HIGH VOLTAGE RECTIFIER POWER SUPPLY FOR


ELECTROSTATIC PRECIPITATOR.

CONTENT
/// POWERCON PAGE 3 OF 17

HT DISCONNECTOR SWITCH FOR STYLE-2

CONTENT
/// POWERCON PAGE 4 OF 17

CONTENTS

ATTENTION

IMPORTANT INSTRUCTIONS

INTRODUCTION

DESCRIPTION OF TOTAL OPERATION

DRAWINGS AND SPARE PARTS LIST

CONTENT
/// POWERCON PAGE 5 OF 17

ATTENTION

These instructions are to be followed when the equipment is received at site.

 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.

 In case of physical damage in transit displacement of parts, missing components


necessary prompt and urgent action should be taken, and this should be reported to the
concerned authorities.

 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.

7.Routine maintenance instructions should be strictly adhered to.

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 .

1. Thermal Power Plant De- dusting of exhaust gases from


boilers.
2. Paper Industry De- dusting of exhaust gases from
boilers.
3. Cement Plant Dust precipitation from air or waste
gases dryers & crushers , rotary kilns
etc.
4. Coal Industry Dust precipitation in steam and gas
heated coal dryers.
5. Chemical & Fertilizer plants. Demisting of gases.
6. Industrial air conditioned Air cleaning.
installations.
7. Paint Industry Separating metal oxides, pigments.
8. Iron and steel Industry De- dusting of waste gases from
blast furnaces.

CONTENT
/// POWERCON PAGE 8 OF 17

DESCRIPTION OF TOTAL OPERATION

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

INTERNAL CONNECTION OF HT SWITCH

CONTENT
/// POWERCON PAGE 10 OF 17

HT DISCONNECT SWITCH SIDE VIEW

CONTENT
/// POWERCON PAGE 11 OF 17

HT DISCONNECT SWITCH

1 2

1) TR SET TERMINAL IS CONNECTED TO FIXED INSULATOR-1


2) FIELD TERMINAL IS CONNECTED TO FIXED INSULATOR-2

CONTENT
/// POWERCON PAGE 12 OF 17

INTERNAL STRUCTURE OF HT SWTICH

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

EARTH SWITCH POSSITION WHEN FIELD CONNECTION TO TRSET

1) HT ON WHEN FIELD CONNECTED TO TR SET

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

EARTH SWITCH POSSITION WHEN FIELD CONNECTION TO EARTH

1) EARTH WHEN FIELD IS DISCHARGE

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

FIELD CONNECTION TO EARTH

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

FIELD CONNECTION TO TRSET

1) FIELD CONNECTED TO TR SET

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 CONNECTION PLATE

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

6.7.4 EARTH DISCHARGE ROD

DESCRIPTION SPECIFICATION

GENERAL DATA:

MAKE M/S. NATIONAL ENGINEERS

QUANTITY 4 NOS.

APPLICATION EARTH DISCHARGE FOR ESP

LENGTH 1 MT WITH MOULDED RUBBER HANDLE GRIP AT

ONE END AND BRASS TUBE AT OTHER END

MATERIAL OF CONSTRUCTION

ROD GLASS FIBRE

CLAMP S.S.

FLEXIBLE WIRE G.I. WIRE (2000 LG)

CABLE SOCKET COPPER TINNED CHROMIUM PLATED

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.

(BOILER – BJ059 & BJ060) DATA SHEET

O & M MANUAL FOR ESP

CONTENT
6.7.5 MECHANICAL SAFETY INTERLOCK
DESCRIPTION SPECIFICATION

GENERAL DATA:

MAKE M/s. ENTERPRISING ENGINEERS

QUANTITY 2 NOS.

APPLICATION MECHANICAL SAFETY INTERLOCKING

ARRANGEMENT FOR 7 FIELD ESP

SL.NO. DESCRIPTION QTY.(NOS)

A ROTARY SWITCH TYPE LOCK WITH KEY 7

(ELECTRO MECHANICAL LOCK)

B KEY EXCHANGE BOX HAVING SEVEN FRONT LOCK WITHOUT KEY 1

AND ONE SIDE LOCKS WITH KEY

C KEY EXCHANGE BOX HAVING SEVEN FRONT LOCK WITH KEY AND 1

ONE SIDE LOCKS WITHOUT KEY

D LOCK WITH KEY MOUNTED IN ISOLATOR OFF POSITION 7

E KEY EXCHANGE BOX HAVING SEVEN FRONT LOCK WITHOUT KEY 1

AND ONE SIDE LOCKS WITH KEY

F KEY EXCHANGE BOX HAVING FOUR FRONT LOCK WITH KEY AND 1

ONE SIDE LOCKS WITHOUT KEY

G KEY EXCHANGE BOX HAVING TWO FRONT LOCK WITH KEY AND 1

CONTROL LOCK WITHOUT KEYS

H KEY EXCHANGE BOX HAVING NINE FRONT LOCK WITH KEYS AND 1

ONE SIDE LOCKS WITHOUT KEY

I KEY EXCHANGE BOX HAVING THIRTEEN FRONT LOCK WITH KEY 2

AND ONE SIDE LOCKS WITHOUT KEY

J KEY EXCHANGE BOX HAVING FOURTEEN FRONT LOCK WITH KEY 1

AND ONE SIDE LOCKS WITHOUT KEY

K KEY EXCHANGE BOX HAVING SEVEN FRONT LOCK WITH KEY AND 1

ONE SIDE LOCKS WITHOUT KEY

K TRAP DOOR LOCK TYPE WITH MIN. 300 MM MS CHAIN WITHOUT 63

KEY

L MS ENCLOSURE BOX FOR ALL KEY EXCHANGE BOXES 3


SUPPLIER’S ADDRESS:
M MASTER KEY M/S. PS POWER CONTROLS 2
PORUR,CHENNAI-600 116
O & M MANUAL FOR ESP

CONTENT
OPERATION & INSTRUCTION

MANUAL OF

INTERLOCKING SYSTEM

FOR ESP

ENTERPRISING ENGINEERS
46-47, A SECTOR INDUSTRIAL AREA, GOVINDPURA,
BHOPAL- 462 023 (M.P.) - INDIA

Ph.No.0755- 2586684, 5284980 (O) Telefax: 0755-2602964


E-Mail: kgbansalee@airtelmail.in

CONTENT
.. 2 ..

INTERLOCKING DEVICES FOR INDUSTRIAL SAFETY:


(1) INTRODUCTION: Interlocking is basically a method of controlling two or
more interdependent operations of one or more equipments, in a
predetermined sequence. If necessary it may be remotely controlled or
time delayed. Industrial operations and manufacturing processes are
continuousally growing in number, complexity and interdependence. These
frequently require to be executed in strict sequence. It is risky to depend on
the skill and memory of the operators for the proper operation of the
equipments and processes.
The need for this sequential operations may be safety to personnel and
equipments or it may be operational requirement. An action done at
the wrong time and under wrong conditions can entail serious loss or grate
damages to personnel and equipments. It is therefore essential that the
interlocking should be positive and incapable of defeat by any
unauthorised means.

(2) INTERLOCKING OF ELECTRO-STATIC PRECIPITATOR(ESP) :


2.1 REQUIREMENT OF INTERLOCKING : ESP's are operated on High
Voltage A.C. System. Hence for the safety of personnel & equipments,
whole system should be fool-proof, such that none of the door can be
opened when the H.V. rectifiers are in the energised condition & none of the
rectifiers are switched-ON, while any one of the door is kept open (The
doors will include all the Inspection doors, Insulator housing doors
and Disconnecting Switch doors). A series of interlocks are so arranged,
to permit operations in pre-arranged sequence, to achieve the above.

2.2 EQUIPMENTS REQUIRED FOR INTERLOCKING :


This essentially consist of
(i) Mechanical Interlock type DL
(ii) Rotary switch with mechanical interlock
(iii) DT Body with chain arrangement
(iv) Key Exchange Boxes (KEB)
(v) Steel Door Enclosure for accommodating K.E. Boxes.

(i) Mechanical Interlock Type DL : (Fig.1)


This is the basic unit of the Interlock System. These Locks consist of a
Mechanism housed within a Brass body. A shaft of round or square cross
section is projected from the rear of the Lock Body. The lock is operated by
inserting and rotating a Special Key in the lock. The Key is free only in one
position and in another position it is trapped in the lock. The lock of one
particular combination can be operated by the Key of that combination
only. The locks are provided with spring loaded caps which will prevent
ingress of dust when key is out. Keys are also fitted with rubber caps to
prevent entering of dust, when key is trapped inside the lock.

(ii) Interlock with Rotary Switch : (Fig.2)


This consists of a rotary switch fitted with a DL type interlock. The
moving contacts of the rotary switch rotate on a centre spindle which is
driven by the shaft of the lock. When the key is rotated anticlockwise, it is
trapped and the switch is ON and when the switch is rotated clock wise, the
key is released and the switch is OFF.
Contd..3

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.

The basic interlock is mounted on a steel bracket, which can be welded


permanently to the door and the sliding bolt is attached to a chain link with a
plate at another end which can be welded to a fixed portion. When the
siding bolt is trapped, the door remain closed and when it is released the
door can be opened.
(iv) Key Exchange Box (KEB) : (Fig.4)
This consists of number of basic unit type DL locks fitted to a steel box. The
box houses a mechanism, arranged such that certain keys are trapped when
others are removed.

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.

2.3 SYSTEM OF SEQUENTIAL OPERATION :


Opening of Inspection Doors :
The Inspection doors can be opened only when the following conditions
are fulfilled.
(i) All the rectifier transformers are to be in OPEN condition.
(ii) All disconnecting switches in OFF position.
(iii) All earthing switches in EARTHED position.

(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.

Closing of Rectifier Transformer by Lock Switch :


All the inspection doors are closed and keys are taken out of door locks.
These keys are trapped in front locks of KEB of inspection doors and
Multiplication Control keys are released. These Control keys are put in the
locks of other KEB that will release the Control key, which is inserted into
the field earth KEB.

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.

(3) MOUNTING PRECAUTIONS :

(i) Switch Interlock :


These Interlocks are suitable for back of board mounting. It should be ensured
that connection are done as per the scheme i.e. the keys are trapped on ON
position and vice-versa.

(ii) Door Interlock : (DT Body with chain arrangement)


These interlocks should be mounted by screw or nuts & bolts and the
lever provided with chain should be aligned with the groove in the Door
Lock.

(iii) Key Exchange Boxes :


Key Exchange Boxes should be fixed at a proper place by nuts & bolts, so
that the movement of keys are easy during operation.

Contd..5

CONTENT
...5...

(4) OPERATION PRECAUTIONS :

(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 :

i) The key of proper inscription is used.


ii) The operating sequences have been properly followed.
iii) The keys in the end lock or front lock are in proper position.
iv) Associated equipments or doors are in the proper position.

(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:

MAKE M/S. ESCORTS HEATERS PVT. LTD.

6.7.6 SUPPORT INSULATOR HEATER


QUANTITY 56 NOS.

APPLICATION HEATING OF ESP SUPPORT

INSULATORS(THERMOSTATICALLY CONTROLLED)

RATED POWER 1 KW

RATED POWER SUPPLY 415 V, ±10%, 50 Hz , 1 PHASE AC

GLAND TWO NOS. OF DOUBLE COMPRESSION

MATERIAL & CONSTRUCTION THE TERMINAL BOX SHALL BE MADE UP OF ALUMINIUM

DIE-CASTING INCOLOY TUBES WITH QUALITY NICHROME

HEATING ELEMENT.THE TUBES SHALL BE FILLED WITH

MAGNESIUM OXIDE AROUND THE HEATING ELEMENT

WITH LOOP IN LOOP OUT FACILITY

O & M MANUAL FOR ESP

CONTENT
CONTENT
INSTALLATION, OPERATION & MAINTENANCE MANUAL FOR
SUPPORT INSULATOR HEATER

ITEM. : 1.0 KW HEATERS


DRAWING NO. : HEA4.1244 Rev03

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:

M/S ESCORTS LIMITED


ELECTRICAL PRODUCTS DEPTT.
RAILWAY EQUIPMENT DIVISION
PLOT NO. 115
SECTOR 24
FARIDABAD-HARYANA 121005

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

The equipment is designed to work on I- Phase, 415 V, 50 Hz.

DESCRIPTION OF THE HEATING UNIT

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 :

Conduct the following test on the heating unit-


- Check insulation resistance with 500 V D.C Meggar between heating element terminals
and body.
- If I.R value is more than 1 Mega Ohm, go ahead with installation.
- If I.R. value is less than 1 Mega Ohm, connect the heating unit to low voltage supply to
improve the I.R value.
This complete the functional testing of the heater.

CONNECTING TO THE MAINS

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

APPLICATION HEATING OF ESP SHAFT INSULATORS

RATED POWER 1 KW

RATED POWER SUPPLY 415 V, ±10%, 50 Hz, 1 PHASE AC

GLAND TWO NOS. OF DOUBLE COMPRESSION

MATERIAL & CONSTRUCTION THE TERMINAL BOX SHALL BE MADE UP OF ALUMINIUM

DIE-CASTING INCOLOY TUBES WITH QUALITY NICHROME

HEATING ELEMENT.THE TUBES SHALL BE FILLED WITH

MAGNESIUM OXIDE AROUND THE HEATING ELEMENT

WITH LOOP IN LOOP OUT FACILITY

O & M MANUAL FOR ESP

CONTENT
INSTALLATION, OPERATION & MAINTENANCE MANUAL FOR
SHAFT INSULATOR

ITEM. : 1.0 KW shaft insulator Heater


DRAWING NO. : HEA4.1232 Rev01

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:

M/S ESCORTS LIMITED


ELECTRICAL PRODUCTS DEPTT.
RAILWAY EQUIPMENT DIVISION
PLOT NO. 115
SECTOR 24
FARIDABAD-HARYANA 121005

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

The equipment is designed to work on I- Phase, 415 V, 50 Hz.

DESCRIPTION OF THE HEATING UNIT

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 :

Conduct the following test on the heating unit-


- Check insulation resistance with 500 V D.C Meggar between heating element terminals
and body.
- If I.R value is more than 1 Mega Ohm, go ahead with installation.
- If I.R. value is less than 1 Mega Ohm, connect the heating unit to low voltage supply to
improve the I.R value.
This complete the functional testing of the heater.

CONNECTING TO THE MAINS

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.

APPLICATION HEATING OF ESP HOPPERS(THERMOSTATICALLY

CONTROLLED)

RATED POWER 0.5 KW

RATED POWER SUPPLY 415 V ±10%, 50 Hz, 1 PHASE AC

GLAND TWO NOS. OF DOUBLE COMPRESSION

MATERIAL & CONSTRUCTION THE TERMINAL BOX SHALL BE MADE UP OF ALUMINIUM

DIE-CASTING INCOLOY TUBES WITH QUALITY NICHROME

HEATING ELEMENT.THE TUBES SHALL BE FILLED WITH

MAGNESIUM OXIDE AROUND THE HEATING ELEMENT

WITH LOOP IN LOOP OUT FACILITY

SUPPLIER’S ADDRESS:
M/s. ESCORTS LTD,
PLOT NO 115,SECTOR-24,
FARIDABAD,HARYANA-121005.

O & M MANUAL FOR ESP

CONTENT
CONTENT
INSTALLATION, OPERATION & MAINTENANCE MANUAL FOR
HOPPER HEATER

ITEM. : 0.5 KW HEATERS


DRAWING NO. : HEA4.1242 Rev01

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:

M/S ESCORTS LIMITED


ELECTRICAL PRODUCTS DEPTT.
RAILWAY EQUIPMENT DIVISION
PLOT NO. 115
SECTOR 24
FARIDABAD-HARYANA 121005

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

The equipment is designed to work on I- Phase, 415 V, 50 Hz.

DESCRIPTION OF THE HEATING UNIT

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 :

Conduct the following test on the heating unit-


- Check insulation resistance with 500 V D.C Meggar between heating element terminals
and body.
- If I.R value is more than 1 Mega Ohm, go ahead with installation.
- If I.R. value is less than 1 Mega Ohm, connect the heating unit to low voltage supply to
improve the I.R value.
This complete the functional testing of the heater.

CONNECTING TO THE MAINS

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:

MAKE . M/s. RESEARCH NEEDS.,

THERMOSTAT FOR SUPPORT INSULATOR HEATER


QUANTITY 2 NOS.

APPLICATION TO CONTROL THE TEMPERATURE OF THE SUPPORT

INSULATOR HEATERS

TYPE ON / OFF

THERMOSTAT RANGE 30 - 200°C

THERMOSTAT POWER SUPPLY NIL

CONTACT TYPE POTENTIAL FREE (1 NO + 1 NC)

CONTACT RATING 110 V AC, 5 AMPS

THERMOSTAT FOR HOPPER HEATER


QUANTITY 14 NOS.

APPLICATION TO CONTROL THETEMPERATURE OF THE HOPPER

HEATERS

TYPE ON / OFF

THERMOSTAT RANGE 30 - 200°C

THERMOSTAT POWER SUPPLY NIL

CONTACT TYPE POTENTIAL FREE (1 NO + 1 NC)

CONTACT RATING 110 V AC, 5 AMPS

SUPPLIER’S ADDRESS:
M/s. RESEARCH NEEDS.,
159, GOVINDAPPA STREET,CHENNAI,
TAMILNADU-600001.

O & M MANUAL FOR ESP

CONTENT
(BOILER – BJ059 & BJ060) DATA SHEET
6.7.10 RAPPING GEARED MOTOR
DESCRIPTION SPECIFICATION
GENERAL DATA:
MAKE M/S. POWER BUILD

QUANTITY 16 NOS.

APPLICATION RAPPING MECHANISM FOR ESP

MODEL NO. G43G01-10/DK74-178

TYPE OF MOTOR SQUIRREL CAGE , 1500 RPM

TYPE OF MOUNTING FOOT MOUNTED (B3)

GEAR TYPE HELICAL TYPE

MOTOR RATING 0.37 KW

OUTPUT SPEED 1.1 RPM

AMBIENT TEMPERATURE 50°C

COMBINED VARIATION ±10%

ENCLOSURE TEFC

DEGREE OF PROTECTION IP 65

INSULATION CLASS ‘F’

POWER SUPPLY 415 V ±10%, SINGLE PHASE, 50 Hz, ±5%

TYPE OF STARTING DOL

DUTY CONTINUOUS WITH OCCASSIONAL PEAK LOAD (S1

TYPE)

LOCATION OUTDOOR

MOTOR FULL LOAD CURRENT 1.0 AMPS

CABLE ENTRY LEFT SIDE PORTION

SUPPLIER’S ADDRESS:

M/s. POWER BUILD LTD,


NO.553 MOUNT ROAD , 3RD FLOOR ,EAST COAST CENTRE,
TEYNAMPET,CHENNAI,TAMILNADU.

O & M MANUAL FOR ESP

CONTENT
(BOILER – BJ059 & BJ060) DATA SHEET

RAPPING GEARED MOTOR

DESCRIPTION SPECIFICATION
GENERAL DATA:
MAKE M/S. POWER BUILD

QUANTITY 14 NOS.

APPLICATION RAPPING MECHANISM FOR ESP

MODEL NO. G43G01-10/DK74-178

TYPE OF MOTOR SQUIRREL CAGE , 1500 RPM

TYPE OF MOUNTING VERTICAL MOUNTED (B3)

GEAR TYPE HELICAL TYPE

MOTOR RATING 0.50 KW

OUTPUT SPEED 2.5 RPM

AMBIENT TEMPERATURE 50°C

COMBINED VARIATION ±10%

ENCLOSURE TEFC

DEGREE OF PROTECTION IP 65

INSULATION CLASS ‘F’

POWER SUPPLY 415 V ±10%, SINGLE PHASE, 50 Hz, ±5%

TYPE OF STARTING DOL

DUTY CONTINUOUS WITH OCCASSIONAL PEAK LOAD (S1

TYPE)

LOCATION OUTDOOR

MOTOR FULL LOAD CURRENT 1.0 AMPS

CABLE ENTRY LEFT SIDE PORTION

SUPPLIER’S ADDRESS:

M/s. POWER BUILD LTD,


NO.553 MOUNT ROAD , 3RD FLOOR ,EAST COAST CENTRE,
TEYNAMPET,CHENNAI,TAMILNADU.

O & M MANUAL FOR ESP

CONTENT
INSTRUCTION MANUAL
FOR
HELICAL INLINE GEARED
MOTORS/REDUCERS

FOOT MOUNTED

B3 GEARED MOTOR B3 INLINE REDUCER B3 MOTOR MOUNT REDUCER


FLANGE MOUNTED

B5 GEARED MOTOR B5 INLINE REDUCER B5 MOTOR MOUNT REDUCER

AGITATOR TYPE

GEARED MOTOR MOTOR MOUNT REDUCER

POWER BUILD LIMITED


POST BOX NO. 28, VITTHAL UDYOGNAGAR – 388 121, GUJARAT, INDIA.
TEL. : +91-2692-231070, 231120, 231170, 232118, 236488 FAX : +91-2692-236559
E-MAIL : infopbl@elecon.com Website : www.pbl.co.in

Instruction manual No.: GM/IM/07/7000


CONTENT
NOTES TO USERS

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. To start with, check the following points to see

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

If geared motors/reducers have to be stored or the operation has to be stopped for


more than 3 months, please follow the procedures given bellow.

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

(d) Before operating geared motors/reducers, please check the insulation


resistance and carry out the inspection of bearing to see there is no
abnormality.

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.

3.3 Cautions for installation of foot mounted type:

(a) Ensure that installation is always performed on a reliable machined


foundation.

(b) Avoid uneven clamping when you lock the unit on the bed.

3.4 Cautions for installation of flange mount type:

(a) Care must be exercised to ensure that installation is always performed on a


machined face.

(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.

4. Connection with the Driven Machine

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

4.2 When the machine is driven by V-belt, chain or gearing

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.

(a) Point of load application on the output shaft:

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.

(b) Tension of chain:

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.

4.3 Dimension of keyway

Dimension of the shaft end keyway is in accordance with DIN 6885.

5. Connection to Power System

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.

Three - phase A.C. Three - phase A.C. Three - phase A.C.


Squirrel cage Squirrel cage Squirrel cage
motor star - connected motor delta - connected motor connected
for direct starting for direct starting for star - delta starting
Operating voltage = Operating voltage = Operating voltage =
high voltage rating low voltage rating low voltage rating
given on the name plate. given on the name plate. given on the name plate.

terminal box of each motor.

6. Lubrication and Lubricants

be made after approximately 300 to 500 operating hours.

ensure that it is properly tightened.

keep off dirt and to reduce wear of sealing lip.

5
CONTENT
Viscosity : 30°E at 50°C (abt. 250 cS)
Flash point : +230°C
Pour point : 20°C

the following characteristic:

Worked penetration : ° C NLGI


abt. 350 ASTM (measured with 50 g cone at 25
Grade O)
Drop point serviceable : Over 150°C down to abt. -30°C

Different types of grease should not be mixed.

Lubricating Table

are given in the table.

OIL CAPACITY OF GEARED MOTORS/REDUCERS

Type Design Design Design Design Design Design


of B3 & B5 B6 & B7 B8 V1 &V5 V3 & V5 Agitator Type
Gear Liters Liters Liters Liters Liters Liters
32 0.5 0.75 1 1.25 1 1.7
33 0.75 1.25 1.3 2.25 2 2.7
42 0.75 1.25 1.3 2.25 2 2.7
43 1.25 2.25 2.3 3.25 3 3.7
52 1.25 2.25 2.3 4.5 4 5.8
53 1.75 3 3.25 5 4.5 6.3
62 1.75 3 3.25 6.75 5.25 8
63 2.5 4.25 4.5 7.25 7.75 8.5
72 2.5 4.5 4.75 9.5 9 13.5
73 3.75 7 7.5 11.5 10.5 15.5
82 4.5 7.5 8 17.5 17.5 24.5
83 7.5 14 14.5 22 20 27
93 10 20 21 30 28 38
103 16 30 32 45 42 61
113/123 37 63 52 120 135 148

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

7. PERIODICAL INSPECTION / REPAIR

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.)

Inspection / Repair Frequency How to determine the item


item necessity of parts replacement
Restretch of chain 6 months If the tension of chain is loose,
restretch it.
Improper tightening 6 months If tightening of bolts is loose, tighten
additionally.
Replacement of oil 1-2 years At every overhaul, or when oil
seal. leak seal age is found outside,
replace oil seal.
Replacement of 5 years If abnormal noise occurs, replace
bearing bearing.

7
CONTENT
8. TROUBLE SHOOTING

Trouble Cause How to correct


Unit does not rotate in Interruption of Check motor terminal voltage or source
no load condition service voltage.
Breakage of wiring Inspect circuits and repair defect.
Open circuit exists Replace fuse, reset overload relay, check
closing breaker.
Breakage of stator Measure resistance of winding and
winding insulation, distinguish defect of winding.
Defect of gear Replace gear
Defect of key of Replace key with a new one.
shaft, sprocket or
pulley
One of three phase Check motor terminal voltage or current,
circuits is open and breakage of fuse or wiring, repair defect.
works as single
phase circuit
Load is too heavy Lower load to rated capacity or raise
capacity.
Bad contact of switch Check motor terminal voltage or current,
repair bad contact of circuit.
Motor Noisy Invasion of foreign Remove foreign particle.
rotates on continuous particle
no load load Wear or damage of Replace bearing
but trouble bearing
occurs on Wear or damage of Replace gear.
load gear
Overload Bad setting or Revise setting value, or replace with
relay acts improper selection of regular one.
overload relay
Load is too heavy Lower load to rated capacity.

8
CONTENT
TROUBLE SHOOTING OF GEARED MOTOR WITH BRAKE

Trouble Cause How to correct


· Brake does not Breakage of circuit Check circuit.
operate Faulty connection Check connection
Defect of D.C. source Replace
Voltage drop Check length of connection
Brake gap is too big Adjust or replace
Distortion of inner disc Replace.
· Insufficient operation 2
GD is too big Lower GD2 or raise capacity of
of brake brake geared motor.
· Braking time is too Adhesion of oil or dust to Disassemble and clean.
long inner disc
· Abnormal Torque and GD2 are too Check load condition and lower load
temperature rise big to rated capacity.
· Smoke and smell Frequency of operation is Lower frequency of operation, or
too high change specification.
Invasion of foreign Disassemble and clean.
particle in brake gap
· Motor beats Brake gap is too big Adjust brake gap
2
· Motor speed does not Torque or GD is too big Lower load to rated or raise
increase capacity.
· Thermal relay works Refer to “Brake does not operate”

9
CONTENT
MOTOR MOUNTED TYPE GEAR SPEED REDUCER

INTRODUCTION

Here are some essential procedures for maintenance, inspection and installation.

1. Point of Motor Mounting

Please note the following points at inspection or on overhaul.

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.

· Special Lubricant “Shaft Lub”

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.

1.5 Tighten up bolts uniformly.

For ordering spares give following details:


1) H.P., R.P.M. and Type of Geared Motor/Gear Reducer
2) Serial Number of Geared Motor/Gear Reducer
3) Required Part No.

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

1 OUTPUT SHAFT 49 SPRING WASHER


2 RECTANGULAR PARALLEL KEY 50 HEXAGONAL SOCKET HEAD CAP SCREW
3 EXTERNAL CIRCLIPS 51 ELECTRIC MOTOR
4 OIL SEAL (MI TYPE) 52 GASKET FOR ELECTRIC MOTOR
5 DEEP GROOVE BALL BEARING/TAPER ROLLER BEARING 53 DEEP GROOVE BALL BEARING/TAPER
ROLLER BEARING
6 THRUST COVER WITH OIL SEAL (EXTERNAL) 54 CYLINDRICAL ROLLER BEARING
7 GASKET FOR THRUST COVER 55 INTERMEDIATE RING
8 HEXAGONAL SCREW 57 HEXAGONAL SCREW (LONG)
9 SPRING WASHER 58 HEXAGONAL SCREW (SHORT)
10 GEAR CASE COVER/AGITATOR FLANGE 59 SPRING WASHER
11 GEAR CASE 60 HEXAGONAL SOCKET HEAD CAP SCREW
12 GEAR CASE COVER GASKET (FRONT & REAR) 61 HEXAGONAL SOCKET HEAD CSK SCREW
13 HEXAGONAL SCREW 62 HEXAGONAL SCREW
14 SPRING WASHER 63 SPRING WASHER
15 THRUST COVER WITH & WITHOUT OIL SEAL 64 DISTANCE PIECE
16 RECTANGULAR PARALLEL KEY 65 RECTANGULAR PARALLEL KEY
17 SPACER 66 LOCK WASHER
18 CYLINDRICAL ROLLER BEARING 67 SPRING WASHER
19 EXTERNAL CIRCLIPS 68 HEXAGONAL SCREW
20 INTERNAL CIRCLIPS 69 HEXAGONAL SOCKET HEAD CAP SCREW
21 INTERNAL CIRCLIPS 70 HEXAGONAL SOCKET HEAD CSK SCREW
22 EXTERNAL CIRCLIPS 71 INPUT HOLLOW SHAFT
23 DOUBLE ROW ANGULAR CONTACT BALL BEARING 72 EXTERNAL CIRCLIPS FOR 1ST PINION
24 RECTANGULAR PARALLEL KEY 73 OIL SEAL (MI TYPE)
25 SPACER 74 INPUT COVER FOR HOLLOW INPUT
26 DEEP GROOVE BALL BEARING 75 EXTERNAL CIRCLIP FOR BEARING
27 EXTERNAL CIRCLIPS 76 DEEP GROOVE BALL BEARING
28 INTERNAL CIRCLIPS 77 GREASE NIPPLE
29 EXTERNAL CIRCLIPS 78 EXTERNAL CIRCLIP FOR BEARING
30 DEEP GROOVE BALL BEARING 79 DEEP GROOVE BALL BEARING
31 DEEP GROOVE BALL BEARING 80 OIL SEAL (MI TYPE)
32 SPACER 81 GASKET BETWEEN INPUT COVER & FLANGE
33 RECTANGULAR PARALLEL KEY 82 FLANGE
34 EXTERNAL CIRCLIPS 83 SPRING WASHER
35 DRAIN PLUG 84 HEXAGONAL BOLT
36 OIL LEVEL INDICATOR 85 HEXAGONAL SOCKET HEAD CAP SCREW
37 BREATHER PLUG 86 SOLID INPUT SHAFT
38 EYE BOLT 87 INPUT COVER FOR SOLID INPUT SHAFT
39 CYLINDRICAL ROLLER BEARING FOR 113/123 88 INSIDE THRUST COVER FOR INPUT SIDE
40 SPACER FOR 113/123 89 HEXAGONAL BOLT FOR INSIDE THRUST
COVER
41 1ST PINION 90 SPRING WASHER
42 1ST WHEEL 91 GASKET FOR INPUT COVER & INSIDE THRUST
COVER
43 2ND HELICAL PINION SHAFT (FOR 2 STAGE ONLY) 92 OUTSIDE THRUST COVER FOR INPUT SIDE
44 2ND HELICAL PINION SHAFT (FOR 3 STAGE ONLY) 93 HEXAGONAL BOLT FOR OUTSIDE THRUST
COVER
45 2ND HELICAL WHEEL 94 SPRING WASHER
46 3RD HELICAL PINION SHAFT 96 INTERNAL CIRCLIPS
47 2ND/3RD HELICAL WHEEL 97 RECTANGULAR PARALLEL KEY
48 INTERNAL CIRCLIP 98 BAFFLE PLATE
99 BREATHER PLUG

19
CONTENT
OUR MANUFACTURING RANGE

Automatic Weighing and Bag Filling Machines

Microprocessor based Electronic Belt Weighers

Microprocessor based Electronic Weigh Feeders

.
Cement, Chemicals, Fertilizers and Steel Industry.

Electronic Metal Detectors


For detection of metallic contamination in bulk products.

Industrial Magnets

Automatic Truck and Wagon Loaders


For automatic loading of filled bags of cement, urea, etc.
direct into trucks and wagons.

from 0.16 HP to 125 HP

Heliworm Geared Motors/Gear Boxes/Gear Reducer


from 0.16 HP to 30 HP

Helibevel Geared Motors/Gear Boxes/Gear Reducer


from 0.5 HP to 30 HP

: SELLING AGENT :
EMTICI ENGINEERING LIMITED
REGISTERED OFFICE :

: BRANCHES : Akaaish Printing & Stationery - V. V. Nagar


AHMEDABAD : ASANSOL : BANGLORE :
Phone : (079) 26406685, 26406686 Fax : 26401363 Phone : (0341) 2205901, 2211726 Fax : 2202038 Phone : (080) 22260219, 22250082 Fax : 22281834
E-mail : sales@ahdemtici.elecon.com E-mail : salesasn@asnemtici.elecon.com E-mail : salesbgl@bglsemtici.elecon.com

BILASPUR : CHENNAI : DHANBAD :


Phone : (07752) 228922, 224122 Fax :223188 Phone : (044) 24349497, 24349237 Fax : 24349643 Phone : (0326) 2306283, 2302320 Fax : 2302320
E-mail : salesbil@bilemtici.elecon.com E-mail : salesmad@mademtici.elecon.com E-mail : salesdhn@dhnemtici.elecon.com

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Phone : (0657) 2428138, 2435382 Fax : 2428015 Phone : (033) 24761861, 24760876 Fax : 24761831 Phone : (022) 22821315, 22820725 Fax : 22870791
E-mail : sales_jns@jmpemtici.elecon.com E-mail : salescal@calemtici.elecon.com E-mail : salesbom@bomemtici.elecon.com

MUMBAI-2 (Goregaon) : NAGPUR : NEW DELHI :


Phone : (022) 26999132, 33, 34 Fax : (022) 28751133 Phone : (0712) 2540771, 2531601 Fax : 2554982 Phone : (011) 23414339, 40, 41 Fax : 23709046
E-mail : salesgorg@bomemtici.elecon.com E-mail : salesnag@nagemtici.elecon.com E-mail : salesdel@delemtici.elecon.com

PUNE : SECUNDERABAD : VADODARA :


Phone : (020) 24329147 Fax : 24329055 Phone : (040) 27844748, 27845250 Fax : 27848317 Phone / Fax : (0265) 2750739, 40
E-mail : salespune@puneemtici.elecon.com E-mail : salessec@seceemtici.elecon.com E-mail : salesbrd@brdemtici.elecon.com

ELECON AUSTRALIA : ELECON SINGAPUR PTE. LTD. : ELECON SOUTH AFRICA :


Phone : 61-2-9521 3511 Fax : 61-2-9521-3522 Phone : +65 2278258, 2278425 Fax : +6502278942 Phone / Fax : +27 (0) 11-4771776 Mobile : +27 (0) 829006829
E-mail : thall@aus.elecon.com Gen. E-mail : elecon_sing@eleconsingapore.elecon.com E-mail : gdramsay@mweb.co.za

CONTENT
(BOILER – BJ059 & BJ060) DATA SHEET
6.7.11 ELECTRICAL HOIST
DESCRIPTION SPECIFICATION
GENERAL DATA:
MAKE M/s GRIP CRANES & HOISTS

QUANTITY 1 NOS.

APPLICATION ESP TRSET HANDLING

CAPACITY 5 TON

HEIGHT OF LIFT 33 MTRS.

TRAVELLING BEAM SIZE ISMB 250 MTRS.

HOISTING SPEED 5 MPM

KW / HP 3.7 KW / 5.0 HP

NO. OF POLE 4 POLE

HOISTING MOTOR SPECIFICATION SPEED 1400 RPM

TYPE B3

DUTY S4 DUTY

MOTOR INSULATION CLASS F

TYPE OF TRAVELLING TROLLEY MOTORISED TRAVELLING TROLLEY

CROSS TRAVEL SPEED 15 MPM

KW / HP 0.26 KW / 0.35 HP

NO. OF POLE 4 POLE

SPEED 1400 RPM


CROSS TRAVEL MOTOR SPECIFICATION
TYPE B3

DUTY S4 DUTY

QUANTITY 2 NOS

FLOOR BY MEANS OF PENDENT PUSH BUTTON


OPERATING STATION
STATION

CONTROL VOLTAGE FOR PENDENT 110V AC

OPERATIONS

SUPPLIER’S ADDRESS:
M/s. GRIP CRANES & HOISTS,
9 / 1A, 3rd STREET,JAYAPRAKASH
NAGAR,GANAPATHY,COIMBATORE-641002.

O & M MANUAL FOR ESP

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.

Project : M/s. SHREE CEMENT LIMITED.,


SHREE MEGA POWER PROJECT,
BEAWAR – 305901.
RAJASTHAN.

P. O. No & DT : MBI059/0112/0/S Dt: 12/07/2010

Equipment : 5 Ton X 33 Mtrs Lift Electric Hoist

Machine Sl. No. : 170/2010

GRIP CRANES & HOISTS.,


Office: 9/1A, 3rd Street, Jayaprakash Nagar, Ganapathy,
Coimbatore – 641 006. Tel/Fax : 0422 – 2331033.
Works: S.F.No: 2/8,2/9, Thelungupalayam Road, Ellappalayam (P.O),
Kariayampalayam Village, Annur, Coimbatore – 641 697.
E.Mail:gripcranes@yahoo.co.in Web: www.gripcranes.com

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.

3. In some hoists a Single Phase-cum-Wrong connection preventor is provided.


Should the hoist not working on connecting to the mains change sequence of
incoming leads in the preventor. The push button station as well as limit switches
will work as adjusted at factory.

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 TO LUBRICANTS RECOMMENDED


PARTS
LUBRICATE H.P INDIAN OIL
Hoisting Gear Box Every 6 months Parthan EP-220 or Sarvomesh SP-257 or
equivalent equivalent
C.T.Gear Box Every 6 months Parthan EP-220 or Sarvomesh EP-257 or
Lithon-3 or Lithon-3 or
Equivalent. equivalent
Wheel bearings Every 2 months Lithon-3 or Sarvogem-3 or
equivalent equivalent
Snatch block Every month Lithon-3 or Sarvogem-3 or
Bearings equivalent equivalent

OPERATING PROCEEDURES AND PRECAUTIONS PRIOR TO OPERATION

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.

Dragging of the load on floor by hoist is to be avoided.

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.

06. DO NOT allows any one to ride on a load being handled.

07. ABIDE all signals given by rigger or signalman.

AFTER COMPLETING THE HANDLING OF LOAD

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.

PERIODICAL INSPECTION AND EXAMINATION INSPECTION

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

(THIS IS TO BE CARRIED OUT ALSO TO HOIST SUBJECTED TO SUDDEN OR UNUSUAL


SHOCK LOADS OR TO MAJOR REPAIRS)

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.

05. CHECK UP grease packed housings of ball/roller bearings.

06. CHECK UP if wire rope is fairly lubricated. If it is dry get it lubricated.

07. FILL UP the gear case with fresh oil as per instructions provided.

ELECTRO MAGNETIC BRAKE AND MAINTENANCE USED WITH WIRE ROPE


ELECTRIC HOIST

MAINTENANCE INSTRUCTIONS FOR SHOE TYPE BRAKE:

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.

TROUBLE SHOOTING AND REMEDY MAGNET FAILS TO PICK UP

01. CHECK UP for loose connection and proper voltage.

02. CHECK UP coil continuity, replace, if burnt out.

BRAKE MAKES CHATTERING NOISE

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

01. CHECK UP main spring setting.


02. CHECK UP liner plate wear.
03. CHECK UP that armature plate of friction plate is not touching to mounting bolts.
04. CHECK UP driving hub and motor shaft are not touching to armature plate at center.

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.

GEAR BOX MAINTENANCE

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:-

a. Inadequate or excessive lubrication.


b. Non-replacement of well used lubricant.
c. Worm gear tooth
d. Worm bearings.
e. Leakage of lubricant.
f. Non-alignment of gear box after dismantling and re-assembling.

LUBRICATION OF THE GEARS

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

TROUBLES CAUSE REMEDY REMARKS


Motor does not start Power supply completely Check Up with lamp In hoist having
Even without load. Cut-off from motor or Single phasing cum
Interrupted. Wrong connection
Preventor. Please
Change sequence
First.
Phase sequence wrong Change two phases ,,
Of main supply
Limit Switch does not Check up movement ,,
release Of levers
One phase is open Check with lamps ,,
Motor does not start. Brake not opening. Examine movement of
But, Contactors are Brake
Working.
Motor defective or Check up operation
Overloaded. Without any load
Where switch is closed Worm bearing allowing Check up bearings and If the motor
A loud roaring noise. The rotor to come in Replace, if worm remains connect to
Motor may or may not Contact with stator. The line under this
Start. Condition, vibration
May injure the
Winding due to
Excessive heating.
Loose connection Check up and rectify The indication of
between some of the This defect is that
Rotor bars and rings motor noise and
vibration on starting
ceases when it has
achieved its speed.
Motor working, but The armature or rotor Rectify by shimming If repair is not made
with noisy operation working loose on shaft up under the key or by at an early stage of
making new key way. trouble both the key
and key way will
wear needing a new
key way to be made
Low Voltage Trouble Low voltage on line Check up the voltage If the voltage
variation is very
high and constant, it
is better to draw the
current to the hoist
through a rectifier
Poor connection Check up and rectify This causes unusual
between rotor bars distribution of
current in the motor
Open circuit of circuit Check up & rectify
short
Low Speed Low frequency of Check up with relevant
voltage instruments
Motor rubbing on stator Rectify on replace
rotor
8

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:

01. Do not operate a defective hoist.

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.

04. Do not lift or transit loads above the rated load.

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.

11. Do not use the limit switch constantly as an operating appliance.

12. Do not disregard the signals given by authorized rigger or signalman.

13. Do not keep the hook hanging down when the hoist is not in service.

**********

11

CONTENT
CONTENT
YET TO RECEIVE FROM VENDOR WILL BE FURNISHED LATER

CONTENT

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