电除尘安装方案-english.doc

PT NWPCI CONSORTIUM WIKA-CHENGDA PT PLNPLTU KALIMANTAN SELATAN 2*6MWErection Procedure of Electrostatic Precipitator (ESP)1. Purpose This procedure is to provide an available plan and ensure a smooth installation for boiler ESP installation.2. Basis2.1 Drawings and documents from SHANDONG YANGGUANG2.2 Drawings and document form Tianjie Group Co.ltd.3Content and work quantity3.1 Open packing, check the amount, compile working instruction, teach-know-how, equipment and tools, instrument and so on.3.2 Foundation acceptance3.3 Base seat installation3.4 Hopper installation3.5 Casing installation3.6 Cathode & anode system installation3.7 Inlet & outlet sealing installation3.8 Stairway and access installation3.9 HV cable installation3.10 Installation of hanging system on ESP top3.11 Installation of corresponding electric equipment3.12 Partial pre-commissioning 4 Conditions to be finished before erection4.1 The equipments and tools, welding rod, oxygen, acetylene and so on are ready;4.2 The foundation of ESP is finished and accepted;4.3 All drawing and instruction manual is ready and appear no fault after examine;4.4 Road and access unclocked;4.5 Construction field is backfilled and compacted.5 Flow chart and relative documents5.1 flow chart 5.2 ESP erection sequence:5.2.1 Foundation5.2.1.1 The screw length of embedded anchor bolt should be correct and without damage. The space between bolts should satisfy design and installation requirement. Anchor bolt should be vertically embedded, and apply anti-rust and anti-damage measure on screw.5.2.1.2 The location, specification, size and quantity of embedded steel plate should satisfy requirement on drawing, and steel plate should be firmly embedded.5.2.1.3 For the relative altitude deviation of foundation column top, measure with theodolite. Use a scale to measure column space and diagonal deviation.5.2.2 Steel bracket installation5.2.2.1 Mark out the centerline of column and cross centerline of the two end, so as to check if the centerline of column coincede with foundation centerline.5.2.2.2 Erect one row (line) as benchmark, and fix them with hard bracket or cable after alignment.5.2.2.3 After that, erect other rows (lines) and instal the bracket with bolt, and inspect them consult with the benchmark, including the verticality of the columns, top elevation and diagonals. Fasten the anchor bolts, and confirm that all measured parameter is correct, then weld column sole plate and embedded steel plate. During welding, measures should be taken to avoid distortion. At last, re-measure the welded steel bracket.5.2.2.4 Steel bracket installation inspection: the maximum deviation of column distance is 3mm; when diagonal is not more than 20m, the deviation should not be more than 6mm, while diagonal is more than 20m, the deviation should not be more than 8mm. The deviation of column verticality equals column length divide 1000, and should be no mire than 5mm; the deviation of horizontal elevation at all columns is 0-3mm.5.2.3 Support installation5.2.3.1 The solid and sliding support should be placed and fixed strictly in accordance with drawing requirement. Pay attention to displacement direction, so as to avoid incorrect installation. 5.2.3.2 Mark a cross line on each upper plane of the support. The solid support should be aligned and tack welded, which will be regarded as a benchmark for other supports. Refer solid support as benchmark to measure center distance, and use theodolite to measure the elevation of all support, and according to elevation deviation, add backing plate on support. Then tack weld the backing plate, sole plate(stainless) and support base plate.5.2.3.3 Fully weld column top plate of steel bracket&support, support and backing plate and stainless sole plate. One welding seam can be finished into separated parts.5.2.3.4 Inspect as per the drawing to see if the support locations are correct or not.5.2.3.5 All solid supports and sliding supports should be on the same level, and the deviation of center distance for two neighbouring support is 3mm. When the diagonal is no more than 20m, the deviation should be less than 5mm; when diagonal is more than 20m, the deviation should be less than 8mm. At the same time, the levelling deviation of all supports is 1mm, and elevation deviation of all top surface is 3 mm. 5.2.3.6 Carefully examine one-way sliding support and two-way sliding support to see if they are finished with sliding board(teflon) and stainless sole plate.5.2.3.7 After installing the whole ESP, carefully examine temporary fixing block for one-way & two-way sliding support, and make sure they are removed. 5.2.3.8 The spherical surface of sliding bearing and friction surface should be wiped with #2 MoS2 lime-base grease or #4 grease.5.2.4 Building of ash hopper 5.2.4.1 Mark on the assembling platform and weld a positioning block refer to wide-mouth dimension of hopper.5.2.4.2 Assemble the upper individual pieces into hopper, and place on the platform upside down.5.2.4.3 Fix the four pieces of hopper plate with but welding respectively, and full weld them after examine the dimensions. Then butt weld the lower part.5.2.4.4 The bracing outside of the hopper should be lapped on each other, and lap joints should be firmly welded, so as to ensure the strength. 5.2.4.5 The spoiler can be withhold after the ash hopper is positioned. (the cindervalve should be installed after clean up the inside of electric field).5.2.5 Ash hopper installation.5.2.5.1 The ash hopper can be erected after overall assembling, and in order to avoid distortion, there should build temporary reinforcing support inside the hopper.5.2.5.2 During erection, pay attention to the length and direction of hopper, avoid any incorrect installation, and make sure the temporary bracing is on steel support.5.2.5.3 After the lower end plate, pressure part and side plate is positioned, align the ash hopper on by one, so as to make the centerline of all outlet flanges on the same line with electric field in length and width, and flange elevation on the same level. Then weld the wide mouth of hopper with lower end plate, pressure parts, side plate and connection location of T beam. The welded location should be air tight and firm, so as to ensure tightness and strength.5.2.5.4 After ash hopper is positioned, the spoiler should be installed perpendicular to air flow direction. Welding should be firm, otherwise the spoiler will accumulate ash and lead to short circuit.5.2.5.5 The welding seam is tight, and the hurt of inside hopper wall should be polished by grinder.5.2.5.6 The approach slabs at the four corner inside hopper wall should have their welding seam grind off, and the upper end between approach slabs and wallboards should be sealed.5.2.5.7 The deviation of hopper wide side is -3-6mm, and centerline of all outlet flanges on the same line with electric field in length and width; flange elevation deviation is 3mm.5.2.5.8 The bracing outside of the hopper should be lapped on each other, and lap joints should be firmly welded, so as to ensure the strength. 5.2.5.9 Weld the wide mouth of hopper with lower end plate, pressure parts, side plate and connection location of T beam. The welding seam should be full, smoothly transited, and of good tightness.5.2.6 Side plate installation5.2.6.1 Before installation, examine the column, wallboard one by one, and rectify the unqualified ones as soon as possible.5.2.6.2 Examine the specification and quantity of column and wallboard, all material should meet the requirement on drawing. Do not install incorrectly.5.2.6.3 The column and wallboard can be separately installed in according to lifting ability of the equipments and site condition, and also can be installed after assembling column and wallboard together. After rectifying the verticality and elevation, and temporary support installed, loose the hook. (Note: the side plate and seal plate on wide column should be withhold after installing the top beam)5.2.6.4 The welding of side plate and isolation plate should be firm, and after welding every one of the plates, check dimension, shape and welding seam quality as per the drawing.5.2.6.5 The verticality of column should be 5 mm of 1/1000 column height; the allowed column distance deviation is 5 mm of 1/1000 column distance on the drawing; the deviation of column is 3 mm; when diagonal deviation is 20m, 5 mm is allowed; when diagonal deviation is 20m, 8 mm is allowed; the verticality of column end and upper&lower end of wallboard to column centerline is 3mm.Installation of upper&lower end plate and pressure parts5.2.6.6 Before installation, examine every upper&lower end plate and pressure parts, and rectify the unqualified as soon as possible.5.2.6.7 Lifting sequence: firstly, lift lower end plate, lower pressure parts, which will be assembled into lower frame with column and wide column; then lift middle pressure parts to form middle frame, at last, lift upper end plate to form upper frame.5.2.6.8 After forming a frame, use bolts to fix or tack welding, then temporarily fix the connecting location.5.2.6.9 Examine the upper, middle and lower frame, if qualified, weld the connecting location and bolts.5.2.6.10 The wide column and pressure parts must be reinforced as per drawing requirement.5.2.7 Installation of walkway 5.2.7.1 The installation of walkway should follow the drawing requirement. The walkway end and bracket is welded on lower end plate and pressure parts, and every location should be firmly welded.5.2.7.2 For the walkway installation, pay attention to the anode positioning which will be installed succedently on it, as well as corresponding dimension of anode.5.2.7.3 The bracing should be installed as per the drawing, fastened and firmly welded.5.2.7.4 Welding of walkway: the walkway and positioning angle steel at rapper side should be welded together, and those are not at rapper side should not be welded. The unwelded parts should be fixed by positioning angle steel.5.2.7.5 The deviation of walkway center should be 5 mm; of walkway diagonal should be 8 mm; and of walkway level should be 3 mm.5.2.8 Installation of top beam 5.2.8.1 Before erection, examine the dimension of top beam, emphasize on clamp dimension.5.2.8.2 Top beam installation should be follow the sequence from inlet to outlet of the ESP, that is, install from 1st to 4th electric field.5.2.8.3 The top beam is an important part in ESP erection, so it must be examined its dimension very carefully, and rectified its deviation in time, so as to ensure the clamps which are hanging from inlet to outlet are orderly arranged.5.2.8.4 After the top beam is erected and aligned, the span deviation of great beam should be 5 mm; and the diagonal deviation great beam be 10 mm, and the deviation of relative height be 5 mm. During welding, pay attention to strength and tightness of the welding seam.5.2.8.5 Caution: the two ends of top beam and connecting location of wallboard channel steel should not be welded together.5.2.8.6 Position the seal plate as per the drawing, and confirm the strength and tightness of welding seam.5.2.8.7 The casing must be aligned by lead plumb, and all dimension should satisfy the drawing requirement. The maximum deviation of casing column is +3mm; the verticality of column and level is 3mm; the horizontality of top surface frame of casing (frame constitute of column, side plate, wide column and upper end plate) should be 10mm.5.2.8.8 The tightening bar and diagonal bracing is pressed and firmly welded. If not specially noticed, casing inside should be fully welded and outside intermittent welded. Besides, all welding seams should be air tight, and height of welding seam satisfy the drawing requirement. Lack of solder, welding omission, slags are not allowed, and the welding joint should be examined and cleaned, so as to ensure air tightness.5.2.9 Installation of platform and guardrail 5.2.9.1 After finishing installing ESP steel bracket, instal the 1st layer of platform and guardrail of ESP.5.2.9.2 The bracket used for installing platform and guardrail can be welded to appointed location before steel support and column is erected.5.2.9.3 When installing platform, confirm the elevation, and leve.5.2.9.4 The welding of platform and guardrail should be firm and steady, and welding seam of guardrail should be grinded, and the equivalent of the corner should be smooth and clean.5.2.9.5 The grating should be evenly arranged and firmly welded.5.2.10 Installation of ESP hopper wind shieldThe wind shield is a key part to prevent dust from dropping, and it can confirm the expansion allowance of anode plate and cathode plate. After installation of hopper, the wind shield can be installed. Wind shield inside hopper can be installed after hopper positioning, and anode positioning wind shield must be after anode plate installation, so as to ensure the accuracy and expansion allowance.5.2.11 Building of cathode framework5.2.11.1 Fabricate corona-proof take-up system in according to drawing and technical requirement, and take-up strength should satisfy the design and simultaneous taking-up of the whole frame of corona proof coil. 5.2.11.2 Make a sample for first cathode frame to make position, and weld after examination. The electrode for welding frame must be heated first.5.2.11.3 Rectify the first cathode frame, and weld in abundance after qualified.5.2.11.4 Cathode frame should be stored in special shelf, and the frame length should be packed up when its length is more than 10m, which is for the convenience of lifting and avoiding distortion during lifting. During erection, hanging points should be increased as per actual condition.Installation of anode plate and cathode frame5.2.11.5 Before erecting plate & frame, fabricate temporary hanger and S-shape hook.5.2.11.6 Erect the anti-waving staff, anti-waving frame strengthening staff of cathode system, with adjusting guiding staff channel steel, adjusting staff of anode system into the electric field, and place the material in order.5.2.11.7 Stand up the anode plate package upwards and fix with rigid support, notice that the package end should be firmed so as to avoid falling off.5.2.11.8 Before erection, open the package and remove packing belt one by one. Prepare necessary fire-fighting equipment, lest that asphalt felt get on fire.5.2.11.9 The package of plate can not enter the electric field until examined to be qualified. The anode plate can be hanged on the top beam through hanging system.5.2.11.10 Correctly differentiate the head and end of cathode frame, then erect the frame one by one, and the framework should be temporarily fixed on the plate panel by S hook or steel wire.5.2.11.11 The framework should be erected vertically or laterally, and when the length is more than 10m, it must apply vertical erection. After erection, check the level, and enter into the electric field after qualified. Unqualified parts should be rectified first.5.2.11.12 The last seven frame should be hung on hanger in advance (temporary hanger should be placed on the two beams first), and then hang on the lifting eye.5.2.11.13 After erecting a section of plate frame, weld cathode beam fracture between the top beams, temporary supporting channel steel, whose location is theoretical location of cathode beam fracture. The channel steel in one section should be at the same level.5.2.12 Erection of cathode beam fracture 5.2.12.1 Use a pin to hang up the cathode beam fracture onto cathode framework.5.2.12.2 Adjust the anode plate, make it align with each other. Instal fixation plate, then weld up the lifting eye of hanging pin, fixation plate and top beam. When hanging pin plate and fixation plate aside the welded lifting eye, make sure the pin plate and panel touch closely. At last, full weld the lifting eye of hanging pin plate, fixation plate and top beam as per the drawing.5.2.12.3 Adjust cathode framework, make it in correct location and plumbed, then firmly tack weld the cathode framework and cathode beam fracture.5.2.12.4 Install the anti-swing control system under cathode and anode. Caution：antiroll bar of anode system should keep enough extension tolerance for its own heat expansion.5.2.12.5 Install beam fracture of anode rapper, and the rapping rod should be plumbed. During welding, tack weld the four corner first, then finish all welding symmetrically. Caution：welding seam on base plate of beam fracture must be fully welded, and the welding height around the beam fracture should satisfy drawing requirement.5.2.12.6 Weld earthing cable of anode plate.5.2.12.7 Weld cathode framework. Weld the framework for positioning first, and the welding seam should be separated into sections, so as to induce distortion.5.2.12.8 Install spoiler aside and on top. 5.2.12.9 Install positioning fork. Caution：at the cross between two ends of positioning fork and side spoiler, the width of side spoiler should satisfy the requirement if ESP expand downwards in commissioning. (hold tolerance of 50mm for expansion) Examine of cathode and anode system5.2.12.10 Use a go gage to examine the homopolar space, polar space, whose deviation should be within 10mm.5.2.12.11 Examine the space side spoiler and polar plate as per requirement on drawing.5.2.12.12 Examine the welding seam between positioning fork and polar plate.5.2.12.13 Examine the cathod