Document KG3V67ZpMm7pvj2wedZYLq0Dw

PRECIPITATOR SHUTDOWN REPAIR GUIDE K-1803 Section I PRE-SHUTDOWN II. .. INITIAL INSPECTION III : CLEANING OPERATION IV POST CLEANING INSPECTION AND REPAIRS A. INSULATORS AND HOUSINGS B. HIGH VOLTAGE CABLES C. RAPPERS D. HOUSING E. EMITTER ELECTRODES _ F. DISTRIBUTOR PLATES G. TRANSFORMER V CHECKLIST AND STARTUP TEST A. FINAL INSPECTION B. AIR LOAD TEST " EL Paso Refinery Refinery Engineering October 1, 1976 Revised January 1981 6407 CtfEV B8 STANDARD OIL COMPANY OF CALIFORNIA ENGINEERING DEPARTMENT-SAN FRANCISCCL SPECIFICATION EG-10L8-A DECEMBER 21, I965 PAGE 1 of b SPECIFICATION NO. EG-1QL8-A SMALL TOOLS' AM) EQUIPMENT 1.0 SCOPE This specification lists the types of items that COMPANY classes as "small tools and equipment" whether recoverable, non-recoverable or consumable. Such Items shall be furnished complete, including accessories and expendable operating parts such as blades, bits, abrasive wheels, etc., and shall be maintained in good condition including replacement of parts as may be necessary. 2.0 SMALL TOOLS-AND EQUIPMENT Adapter, Hose,-Pipe^ Thread Adze Anvil, Blacksmith Apron Arbor Auger Awl Axe . Bar, Claw, Crow, Pinch, etc. Barrel, Trash Belt, Safety w/strap Bender, Hydraulic, Manual Bevel Beveler, Transite Binder, Load Bit, Auger, Carpenter " Blades, All Types Blanket, _ Wool, . Rubber .. Block, Chain, Rope, Cable, etc. Boots, Rubber Box (Bag), Tool Brace, Rachet CHEV B8 6400 Broods . . ... Brush, Wire, Paint, etc. Buckets . Cable, Welding, Electrode, Ground, 60C Calipers Cans Cart, Concrete, etc. Casters Caulking Tool (Yarning Iron) Chain, Surveyor, Measuring, Steel Loading Charger, Battery Chisels, All Types-Hand, Pneumatic Chuck, Taper, Drill Clamp, Pipe Aligning, Saw, Carpenter, etc. Clip, Wire Rope Clipper, Bolt Coat, Rain . Connector, Welding Cable Conveyor, Gravity Roller Cooler, Drinking Water Cord, Electric Extension Coupling, Hose Crimper, Electrician's Cutter, Bar, Wire, Pipe-Hand, Pipe-Geared, Gasket, etc- Lanterns, All .Types Lead Joint Runner Level, Hand, Line, etc. Light, Portable Flood Lighter, Torch Line, Mason, Chalk, etc. Lubricator, Air Line STANDARD OIL COMPANY 0? CALIFORNIA ENGINEERING DEPARTMENT - SAN FRANCISCO SPECIFICATION EG-1048-A DECEMBER 21, 1965 PAGE 3 of 4 Pouch, Tool Protractor ' Puller, Nail, Wire, Spike, Rod Pulley Pump, Hand, .Barrel,.Sump, Test Punch, Center, Back, out. Hob, Gasket, etc. Mallet Manometer, Portable Field Mandrel, All Types Mattock Maul Mender, Hose Meter, Vibration, Volt, Amp, etc. Micrometer Mover, Freight Car, Hand Radio, Portable, Two Way Intercom Rake Rasp Reamer, Pipe, Bridge, Burring, etc. Regulator, Welding Gas Respirator, Dust (incl. refill) Roller, Riggers Rope, Manila, Wire Rules, .All' Types Nipper Nozzle, Hose, Nut, Die Nut, Driver Weld, . etc. Oiler, Can Oven, Welding Rod Pail . Paving Breaker, Pneumatic Peavey Pick Pin, Drift, Barrel, Bull Pincer Plane Pliers Plumb Bob Point, Trammel Pole, Pike, Range Pot, Melting, Fire CHEV B8 6402 Salamander Sander, Disc, Belt Saw, Portable, All Types-Hand, Power Scraper, Bearing, Miscellaneous Screwdriver Screw stop Screw plate (set) Seriher Set, Nail, Rivet Shackle Shear, Bar, Tinners Sheave Sheeting, Plastic, Paper Shield, Face Shovel Sleeve, Morse Taper Shank Sling, Canvas Pipe, wire Rope, Nylon Snip, Tinners Socket Set Soldering Iron Spade Spike, Marline Square, Combination, Framing, Staple, Tacker Star Drill Stencil, Steel, Brass, Faper etc. 0 SCOPE fVI'ANDAnn on. COMPANY op' CAt.r?OrffllTA IWiMYMUNO lJ|i!J'/\HTMIW'l'-OAN mmrimXl SPECIFICATION' EG-1049-c DECEMBER 2.1, 1965 PAGE I of 1 SPECIFICATION NO. EG-lOLd-C SUPPLIES Thtn flpivcl I'l.ont;tori Hobs bho bypnn of I bemn COMPANY civusnoo an "supp.l !.0s', " whether tncorpora bod inbo the flninhed work or used In Uir course of covin I ruct.1 on. ' 0 SUPPLIES Acid Adhesive - Alcohol Antifreeze (not forconstruction A-equipment) Babbitt . - Carbide Carbon Tetrachloride Chalk Coal and Coke Compound, Cleaning, Pipe, Thread, Grinding Cotter Pin Crayon Creosote Cup,Drinking Disinfectant Emery Cloth Explosive s ` -F-ir-st-AidHSupplxes- Flux, Brazing, Weidi-ngFuse (except for permanent plant use) Gasket Paste Glue Glycerine Graphite ... Grease (except for .construction equipment, and tools) Ice Keel (Lumber Crayon) Kerosene --- - Lamp, 120 Y Electric Litharge : '. Lubricant, Thread Cutting,..JLLecxriC Wire Pulling Nails Oil, All Types (except for lubrication and:fuel for construction equipment -.-and tools.). Paint (for Erection Marking) Paper, Sand Paper, Toilet Paste, Solder Putty Rag Rust Preventive Salt Tablets Screen Cloth, Wire Screws Shim Soap Soap Stone Solder Stake, Survey Staple s ... , Tape, .Adhesive., .Masking^_Frlction,.. Rubber, Plumbers, etc. Tacks Towel, Paper Twine Washing Powder Waste, Cotton Weld Rod Welding Gases Wire, Tie,' and Miscallaneous Wool, Steel . CHEV B8 6404 Specification E-1073 Engineering Department June 17," 1952 'Page 1 of 2 SPECIFICATION NO, E-1073 DEFINITION OF "EQUIPMENT RENTAL RATES11 IN CONSTRICTION CONTRACTS 1.0 SCOPE This specification defines the costs included and excluded in rental rates for construction equipment and specifies the method of application of these rates, 2.0 DEFINITION OF RENTAL RATES 2.1 Operating Period Equipment rental rates shall be based on operating periods of 8 hours per clay, 56 hours per week and 2i|0 hours per month, 2.2 Costs Included Equipment rental rates shall include all maintenance, painting, and --incidental repairs on the equipment throughout' the construction period 2.3 Costs Excluded Equipment rental rates do not include the following items of expense: 2.31 Freight from shipping point to destination and the return freight at the expiration of the rental period. 2.32 Loading and unloading charges if necessary for loading on a car or unloading from a car. 2.33 Wages of Operators 2,3U Cost of fuel and lubricant and wages paid for fueling and lubricating. 3.0 APPLICATION OF RENTAL RATES 3.1 Rental Period The rental rates shall apply only during the time the equipment is actually operated at the construction site. CHEV B8 6405 I. PRE-SHUTDOWN ITEMS A. Make pressure survey of all insulator housings. May need to replace air filters to get sufficient supply air. Note any housings with low pressure. Check regulators by swapping positions. Order parts for shutdown. B. Arrange for service engineer if desired. C. Check gear reducer drives. Check oil level, chains, and overall condition. D. Inspectors note gas leak locations. -1- CHEV B8 6408 II. INITIAL INSPECTION - PRECIPITATOR DIRTY A. Large and Small Insulators and Housings 1. Note degree of dust buildup and condensation in housings. (The air purge is designed to prevent both conditions.) 2. Note degree of corrosion to housing. 3. Note the problems to be corrected. B. High Voltage Cable 1. Note extent of dust buildup and signs of condensation. 2. Check for corrosion damage to housing and cable. 3. Open all the inspection plates in the high voltage cable system. Check for dust buildup. Examine all the insulators for cracks and tracking. C. Gas Inlet and Outlet Distribution Plates 1. Open side manways and obtain Entry Permit. 2. Check and note pattern of dust buildup. Also check for plugging. The distribution plates are designed to provide a uniform flow across the unit. 3. Check for cracks, distortion and overall corrosion. 4. Check for accumulation of catalyst debris in the inlet pipe and note whether any of the distribution holes are covered. Note - Inspectors may want manways opened. D. Precipitator Housing 1. Note dust buildup on the interior members of the housing. There should be an even distribution showing a balanced flow. 2. Note the dust buildup on collector plates. They should have a slight buildup. Large buildups suggest rapping problems. CAUTION: Avoid stepping on the emitting frame and shock bars. Add wooden planks for walking support before entering,, -,0_ CHEV B8 6409 III. CLEANING-OPERATION A. Insulators and Housings Initials Date 1. Remove the old packing from the packing groove. Install new packing. 2. Power wire brush the entire compartment interior EXCEPT for the insulators. Vacuum all the catalys dust and scale from the compartment. 3. Gently clean the insulators. Use caution so as not to chip or scratch the ceramic materials. Clean the insulators with a soft cloth and solvent. 4. Just before closing the lids - rewipe the insula tors with denatured alcohol on a soft cloth to remove dirt particles and moisture. 5. Set yard air to purge system and check that each housing holds air pressure. 6. Test eight purge relief valves (3.5 psi) and re-install. B. High Voltage Cables -- 1. Vacuum or air blow the high voltage cable housing of all loose scale and catalyst dust. 2. Clean all the insulators with the solvent soft cloth system. 3. Just prior to- closing the units, dry the insulators with the denatured alcohol wash. C. Precipitator Internals 1. Water wash the entire interior of the precipitator Use fire water to rinse the unit.as clean as possible. -3CHEV B8 6410 IV. POST CLEANING INSPECTION AND REPAIRS A. Large and Small Insulators and Housings 1. Inspect the insulator housings. Look for holes and potential leakage sites. 2. Make a close thorough examination of all insulators for cracks, rough spots, absence of glaze, tracking, etc. A bright light will help locate insulator flaws. 3. Mark damaged units for removal and replacement. 4. Check packing on grid rapper shafts to prevent excessive leakage of purge air. (Orifice is sized for 0.5 CFM/housing). B. High Voltage Cables 1. Check the wires and conduit for mechanical problems. 2. Inspect the insulators for cracks, tracing, etc. 3. Mark areas for repair or replacement. C. Collector and Emitter Rappers Expect considerable wear requiring welding repairs or new parts. Hopper work platforms may be needed. 1. Repair worn or bent guide fingers and pipe sleeves over guide fingers 2. Check for eccentric wear of anvils and hammers (wheels) which indi cates poor alignment. Hammer hits below center of anvil 1" when cold. Straighten shock bars if bent. 3. Check and if necessary replace worn bolts through plate extensions. Shock bars must clear bars supporting guide fingers by 2" minimum when cold. 4. Each shock bar and related plates should swing - freely. (It may be necessary to remove temporary planks to check). Shock bars should contact each plate at rest, so that each plate is impacted at the same time. Shock bars should return to this position after each rap. 5. Check rapper pillow block bearings. Replace if there is excessive play. 6. Check emitting rappers. Expect to build-up, hard face, and grind smooth the cams and trip arms. Check shaft collars and split bearings. ~ " 7. Run all systems before starting and check opeation.. . CHEV B8 6411 IV. POST CLEANING INSPECTION AND REPAIRS (continued) D. Precipitator Housing 1. Inspect the shell for cracks and holes. Define repairs as required. 2. Note the condition of the structural members and the welds. E. Emitter Electrodes (Wires) NOTE: Discharge electrode failures are the most frequent failure made in the precipitator. Failures are typically caused by corrosion, fatigue, or electrical arcing. 1. Check for broken or loose wires. Proper tension is 15-30 lbs. 2. Replace all wires in rows. This will be done sequentially south in the West. Bank and then north in the East Bank to periodically replace all electrode wires. Spread adjacent plates to provide, access room. Installation of wires requires extreme care to avoid kinks or strains. Wires must be prestretched to 8'-0" to 8'-3" with anti-kinking device shown in Sketch A. A hooking tool to aid in removing and installing wires is shown on Dwg. 4MSK-516. Carefully inspect removed wires for evidence of metal loss. This must be in Inspection records as a guide for eeplacement rate. Cut off one end so wire cannot be accidentally reused. 3. Note the condition of existing wires. Look for notches, wear points or obvious failure points. Especially check the J hangers on both ends of the wires. - 4. Examine the entire support frame especially the welds and support hooks. 5. Check that the entire frame is level and that the wires are parallel to the collector plates. The wires should be centered between the two adjacent plates. (Plate to wire distance 4^'" + V'.) Mark faulty sections for repair. Tack weld nuts on diagonal bracing. (See the attached Drawing #3ESK-8) NOTE: According to Buell, 10% is the upper limit on scattered missing wires. Replace wires if many wires are missing within a row or section. Spread adjacent plates to provide access room. " 6. Replace. rows of emitter wires as a step toward complete replace ment, Stock No. KP-B1-4. Check the hooks and hook welds on each end of wires replaced. Pre-stretch new wire per drawing to 8'-3" (+0" or -3"). The force required to do this is about 50 lbs. If overstretched or kinked, the wire is ruined.. Inspect removed wires carefully for end wear, notches and burns as a guide to replacement schedule of others. Junk old wires. CHEV B8 6412 POST CLEANING INSPECTION AND REPAIRS (continued) F. Gas Inlet Distribution Plates 1. Check for plugging of the distribution holes, corrosion, or distortion of the plates. 2. Note any items that could prevent an even flue gas distribution within the inlet section. G. Transformer . Sample transformer oil and test insulation level. If"it is below 22,000 volts replace or filter oil. Retest. Add oil if necessary. -6- CHEV B8 6413 V. STARTUP CHECK LIST - FINAL INSPECTION AND TEST A. The following items must be checked by the Unit Operator and the Inspector or Engineer prior to final closing. 1. Insulators & Housings (Ready to Close) a. Check that all units are clean and dry. All repairs are complete. Initials Date b. Check that gaskets and seals are in place. c. Trial -run air purge. 2. Collector & Emitter Rappers (Complete) a. Check all internal repairs. b. Check external system - motors, oil levels, etc. c. Turn on the rappers for a trial run. Check inside and out for proper operation. 3. High Voltage Cable & Housing (Ready to Close a. Check that all repairs are complete. b. Insulators should be clean and dry. c. Check all gaskets and seals. 4. Emitter Electrodes - Wires (Ready to Close) a. Check that the frames are level and the wires are centered between the plates (4%" + V distance. b. Check that all hook and wire replacement work is complete. c. Check that there are no materials to cause a plate to wire short. 5. Collector Electrodes -r Plates (Ready to Close a. Check that the plates are plumb and parallel. All plates must be straight. b. Check that the plates are resting against the shock bar for proper rapping. CHEV B8 6414 -7- V. CHECK u ;;( ' FINAL 1 MHI'KCT 1 ON AND T TK!!' (<,niil' 1 nui'd) lull I a I I la I r. Ch nil 1 Ini 1 1 In- p 1; 11 i : i 1111 v 11 ') " 1 m i*pn in; 11 hi ill i hn p 1 ill r< hnl 1 mu . d. Ch erk _ 1 Iml nvc i \'i 1 1 i i*p;i 1 i' wiirl; 1 :i rump 1 (* l < ' . 1 II 1 el HIM i 1 lull 1 mi I'hil.mi (Ki'iuly 1 t> C 1 niu*) /i. Ch cell 1 ll/ll 1 In* p 1 ,i l t*s ,*i n* imp 1 "KK1 d n ml i i 1 1 i'c[ .< I n: 11 re romp I cl c . 7. Housing At Hoppe rr. {Ko/itly l.n Close) ___ a. Check r.lwil. tho she I I and support: work has been completed. . b. Check that all work materials have been removed and door seals are in good condition. c. Replace hopper dump valves. B. Air Load Test 1. After all work is complete make an "AIR LOAD" test. Push doors closed, but have electrician on side door platform. Energize power supplies, observe operation of fast and slow voltage ramps, and record operating data without rappere, and with rappers operating. If sparking occurs below volts try to locate sparking by looking through doors. DO NOT ENTER. This check is easier after dark. 2. Shutdown and secure electric power and attempt to locate and correct spark-over problem. Retest if any changes are made. Initials Date 3. Get operator approval of final Air Load Test, CH& So 641.5