Steel Support, Erection: Electrostatic Precipitator Type F, FM and C

.
Steel Support,
erection
Electrostatic Precipitator
Type F, FM and C
Approved date: 27-jun-2012

Created by: KEP
Approved by: LGA
Doc. No. 52281-04-4.2

Steel Support, erection
52281-04-4.2
List of contents:
Page:
1 Generel notes ............................................................................................... 3

2 Structure of support system ............................................................................ 3
3 Erection preparations ..................................................................................... 7
3.1 Inspection of the concrete foundations ............................................................. 7
3.2 Inspection of the materials supplied ................................................................. 7
4 Erection planning .......................................................................................... 7
5 Mounting of steel support system .................................................................... 8
5.1 Mounting and grouting of anchor bolts ............................................................. 8
5.2 Mounting of columns, struts and diagonals....................................................... 11
6 Erection of precipitator housing ...................................................................... 14
7 Final work ................................................................................................... 15
Enclosure:
Text reference is made to

instruction manuals:
Electrostatic precipitator,
erection manual
General workshop instructions 520530-E
Text reference is also made to the

following drawings:
(Forwarded under separate cover)
1. Load drawing for electorstatic precipitator

2. Assembly drawing for supports
The information transmitted by this document is the proprietary and confidential property of FLSmidth
2/15 and may not be duplicated, disclosed or utilized without written consent from FLSmidth.
Steel Support,erection
52281-04-4.2
1 Generel notes
The electrostatic precipitator type F, FM and C is designed for cleaning of exit gases with
temperatures up to 400°C. The precipitators consist of one or several compartments
comprising one or several electorde fields.
2 Structure of support system

Each electrode field is carried by gantry structures, with the gantries being supported by
vertical supporting columns in two or three ranges.
Struts are used for diagonal bracing of the columns in one range; the struts pass under the
precipitator along one side of the bottom hopper.
The columns and struts are supported by steel bearings, which are fixed to concrete
foundations by means of grouted anchor bolts.
To assure free thermal expansion of the precipitator in the horizontal plane, each column head
and column base is so designed that their apexes are free to move from two fixed, vertical
planes at right angles to one another.
These two planes intersect in a fixed, rigid column, the fixed-point column, from which the
precipitator is able to expand in all directions.
All vertical columns incorporate a rocker bearing shaped hinge at the column head and base.
At the top the struts are fixed to vertical columns by welding in that range which contains the
fixed-point column, attached at the bottom to the foundation through journal bearings with a
hinge bolt so that the struts are able to follow the thermal expansion of the precipitator in the
longitudinal direction.
The fixed-point column and the column(s) opposite the latter crosswise to the precipitator, are
held in place by means of diagonals in the longitudinal direction of the precipitator.
In Figs. 1, 2 and 3 examples are given of the primary structure of the following 3 support con-
figurations for one single precipitator compartment:
Fig. 1: Low type with more than 4 sets of columns.
Fig. 2: High-rise type with more than 4 sets of columns.
Fig. 3: High-rise type with 4 sets of columns.
The structural principles are the same for precipitators having a centre column. Reference is
made to the assembly drawing which shows the exact design.
The letters A, B and C and the numbers 1, 2 ...... n are used to designate the positions can
thus be identified by means of a number/letter combination, f.inst.: F1A, F1B etc.
and may not be duplicated, disclosed or utilized without written consent from FLSmidth. 3/15
52281-04-4.2
Fig. 1
Foundation
Fn+1, A
Diagonal
Column
Foundation
Fn+1, C
Diagonal
Hinge
Rocker bearing
Strut
Foundation Column
F1, A
Fixed-Point column
Foundation
F1, B
Foundation
F1, C
Typical standard steel support
(Low type)
Single precipitator compartment
52281-04-4.2
Fig. 2
Column
Diagonal
Diagonal
Foundation
Fn+1, C
Strut
Hinge
Foundation Rocker bearing
F1, A
Column
Foundation Fixed-Point column

F1, B
Foundation
F1, C
Typical standard steel support
(High type)
52281-04-4.2
Fig. 3
Diagonal
Diagonal
Strut
Diagonal
Foundation
F1, A
Foundation
F4, C
Foundation Column
F1, B
Fixed-point Column
Foundation
F1, C
Typical standard steel support (4 column ranges, high type)

52281-04-4.2
3 Erection preparations
3.1 Inspection of the concrete foundations
Check that the recessed foundations have been made correctly in accordance with the loat
and assembly drawings.
Check the position of the foundations in relation to the buildings connected with the
electrostatic precipitator. The contractor and FLSmidth is to be notified in case of any
unacceptable discrepancies.
3.2 Inspection of the materials supplied
The supplied quantities with respect to anchor bolts with nuts, lock nuts, retainer washers
and disc springs, welding electrodes, rocker bearings, journal bearings as well as columns,
diagonals, and struts must be compared with the specifications given in parts lists and
shipping documents. All parts to be examined for damage sustained in transit.
4 Erection planning
Planning is required before erection is commenced as described in the erection manual for the
electrostatic precipitator.
It is advisable that the pendular steel support system be erected under the supervision of the
precipitator expert.
52281-04-4.2
5 Mounting of steel support system

5.1 Mounting and grouting of anchor bolts
See load and assembly drawings.
Note the position of the fixed-point column and its struts and diagonals.
Check on the assembly drawing whether any of the rocker bearings are equipped with
shear channels on the underside, i.e. welded-on HE-steel sections etc., see Fig. 6. In the
affirmative, the position of these special-type bearings must be noted.
Normally, these bearings will only be placed under the column base points from where the
diagonals emanate as well as under all journal bearings for struts.
Parallel strings, indicating the system lines A, B and C, must be stretched out in the
longitudinal direction of the electrostatic precipitator.
Check the position of recesses in foundations in relation to the position of the strings.
Before the foundation recesses are grouted, the anchor bolts must be fastened in the
correct position. This operation requires the usage either of the bedplates supplied or
templates manufactured at site. See proposal for temporary attachment of anchor bolts in
line B in Fig. 4 and 5.
Centres to be marked out at the top of the rocker bearings.
Anchor bolts for provisional surface proofing to be cleaned.
Spacer bars to be welded on at the base of the anchor bolts. Place the first set of bolts
with rocker bearing/template on foundation F1C.
After adjustments have been made with respect to plane and height by means of a
theodolite or a levelling instrument, the bedplate/template must be fixed firmly to the
foundation - through tack-welding if required - as shown in the example given in Fig. 4.
Remaining bolt groups in line C to be positioned and fastened with correct interspacing
and with the string used as benchmark. Measurements must always be started at the first
base, F1C, in order to avoid an accumulation of errors.
Afterwards, anchor bolts must be placed in foundation F1A in accordance with string's
position and also according to the calculated diagonal measurement from the centre of the
last rocker bearing in line C, point F(n+1)C.
Next step involves positioning of the remaining bolt groups in line A with correct inter-
spacing and with the string used as benchmark.
Check the diagonal measurements.
52281-04-4.2
Fig.4
Example of provisinal anchor bolt attochment in line B.
Assembly drawing
Bedplate or
See load and
template
UNP, to be removed
prior to grouting
Wedge
Recess for
grouting
Shear steel section
Anchor bolt
Welded-on spacers
Note position of welding
52281-04-4.2
Fig. 5
Example of provisional anchor bolt attacment in line B.
Clamp bolt Recess for grouting
UNP
Wedge
Foundation
UNP
Anchor bolt
(Fig. 4)
Bedplate or template
Recess in
foundation
(Fig. 4)
Anchor bolt
52281-04-4.2
Anchor bolts with bedplate/template for struts to be placed in line B.
All bedplates for vertical and inclined columns must be true to spirit level.
Anchor bolts to be adjusted to correct height by means of the anchor nuts over and under
the bedplate/template; check whether it is necessary to attach the bolts at the base when
grouting is made.
Grouting of foundation recesses to be carried to level 50 mm below the upper edge of the
foundation, but only up to level approx. 20 mm below possible shear channels.
After due setting of the concrete around the anchor bolts, possible templates must be
replaced by the bedplates, whereafter the actual mounting of the standard steel support
system can be commenced.
5.2 Mounting of columns, struts and diagonals

See load and assembly drawings.
Rocker bearings to be readjusted by means of the adjusting nuts and anchor nuts to be
tightened, with backnut, to the upper side of the bedplate.
Note!
Always ensure that the shear channels are placed in accordance with the
directions given on assembly drawing.
Lift the columns, see Fig. 6, and lower them down over the anchor bolts and/or possible
erection bolts. These bolts must be tightened against the upper side of the column
baseplate.
Crane to be removed when the column is plumb.
Longitudinal erection irons to be mounted for provisional stabilisation and maintenance of

the column distance in line A and C. An example is given in fig. 6 as to how the erection
irons are fixed.
The above-mentioned erection irons, templates etc. may vary from one erection job to
another, and, therefore, these items are not included in the FLS supply.
Struts to be lifted into position, and anchor bolts in line B to be attached to the upper sides
of the baseplates.
Afterwards, the struts must be carefully attached to the vertical columns in line C,
whereafter these assemlies are carefully tack-welded.
It is advantageous to perform this welding operation on a firm base at ground level

before the columns are erected. Elements to be absolutely horizontal before welding is
started. The correct distance between strut and column to be secured by means of an
erection iron at the base. Erection iron to remain fitted during erection of the columns.
52281-04-4.2
Fig. 6
Example of standard steel support section
at fixed-point column (high type)
Lifting eye or
smilar
Provisional bracing
For erection
Example of diagonal which

Is field-welded to columns
After alignment of the
latter
Fixed-point column
Column
Anchor nuts with

backnut
Disc springs,
If fitted
Adjusting nuts to be
Shear channel relaxed prior to
re-grouting
52281-04-4.2
Remove the longitudinal erection irons which stand in the way, see Fig. 6, and tack-weld
the diagonals in line A and C to the columns.
The whole pendular steel support system must now be aligned as follows:
Adjust the nuts on the rocker bearings if readjustment is required.
Align the columns in line A and B so that the column heads are on line, placed at the
correct level plus/minus 1 mm.
Check that the columns are plumb.
Check that there is similarity between the distance between the columns on lines A and C
and the corresponding dimensions between the gantries on the precipitator housing.
Finish welding must always be made with basic electrodes and must be performed by
certified welders.
Electrodes to be heated to 150-200°C for approx. 2 hours so as to ensure that they are
absolutely dry prior to usage.
Prior to welding, pre-heating is required as follows:
Where the columns are made from Mat. 1100 or Mat. 1110 (see parts list) and where
welding is performed in a moist environment or at temperatures below the freezing point,
the columns must be pre-heated so that - as a rule of thumb - they cannot be touched
within a distance of 75 mm from the welded joint.
Where other steel grades are used for the manufacture of the columns, the zones around
the joint must be pre-heated to 150-200°C before welding.
All welding for the given a-dimensions to be performed in accordance with the directions
given above.
Welded joints to be checked for flaws as indicated on the assembly drawing and a
template must be used to check the a-dimensions.
See general workshop instructions: Welding symbols.
All bedplates to be supported through the insertion of shims as shown in the FLS erection
manual for the eletrostatic precipitator.
Adjusting screws under the bedplates to be relaxed, and the anchor nuts to be tightened
against the upper side of the bedplates.
52281-04-4.2
6 Erection of precipitator housing

After the pendular steel support system has been mounted and after inspection of all welds
and a-dimensions, the next step involves erection of the precipitator housing.
See FLS erection manual for electrostatic precipitator.
Type F and FM:

First mount a precipitator housing gantry above the fixed-point column and fix the latter by
means of 4 wires with wire strainers or by similar means.
Crane to be disengaged when the gantry is absolutely plumb.
The remaining gantries must now be mounted in accordance with the directions given in the
erection manual for the precipitator housing.
Type C:
For type C it is of secondary importance which gantry is first mounted.
Type F and C:
During the erection of the precipitator housing, where the dead load of the precipitator is
small, an assessment, based on the erection sequence chosen and the local conditions of
shelter, must be made to determine the extent of safety measures required in order to protect
the precipitator housing extreme wind loads.
In certain earthquake zones special demands are made, f. inst. with respect to anchorage of
the gantries of the precipitator housing to the top of the pendular steel support system. In
such cases, a description of these details will be featured on the drawings.
After the precipitator housing has been erected, all bedplates must be grouted with shrink-
proof mortar, e.g. "EMBECO 636 PLUS GROUT" or “MASTERFLOW 928” in accordance with the
directions given by the firm supplying the mortar.
52281-04-4.2
7 Final work
Remove the provisional erection bracings between the columns and possible erection bolts on
the bedplates as described on the assembly drawing. For instance a black PVC tube (plastic
tube) can be fitted on the anchor plates where the nut has been removed.
Where the assembly drawing shows anchor bolts led through the baseplates of the column, the
anchor nuts must now be tightened against the upper side of the latter and secured with
backnuts. This always applies for two bolts in line C as indicated on the drawing.
Where the assembly drawing indicates that the anchor bolts are equipped with disc springs,
these springs must now be fitted whereafter the anchor nuts are lightly tightened against the
springs.
Afterwards the gaps between the anchor nuts and the upper side of the column baseplates
must be measured, whereafter the nuts are screwed further down against the baseplates with
a travel rate corresponding to that indicated on the assembly drawing. Finally, the nuts must
be secured with backnuts.
---o0o---

Steel Support, Erection: Electrostatic Precipitator Type F, FM and C

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Approved date: 27-jun-2012

Doc. No. 52281-04-4.2

1 Generel notes ............................................................................................... 3

Text reference is made to

Text reference is also made to the

1. Load drawing for electorstatic precipitator

2 Structure of support system

Fig. 1: Low type with more than 4 sets of columns.

Fig. 2: High-rise type with more than 4 sets of columns.

Fig. 3: High-rise type with 4 sets of columns.

Foundation Fixed-Point column

Typical standard steel support (4 column ranges, high type)

3.2 Inspection of the materials supplied

5 Mounting of steel support system

Centres to be marked out at the top of the rocker bearings.

Anchor bolts for provisional surface proofing to be cleaned.

Check the diagonal measurements.

Shear steel section

Clamp bolt Recess for grouting

Anchor bolts with bedplate/template for struts to be placed in line B.

5.2 Mounting of columns, struts and diagonals

Crane to be removed when the column is plumb.

Longitudinal erection irons to be mounted for provisional stabilisation and maintenance of

It is advantageous to perform this welding operation on a firm base at ground level

Example of diagonal which

Anchor nuts with

Adjust the nuts on the rocker bearings if readjustment is required.

Check that the columns are plumb.

Prior to welding, pre-heating is required as follows:

See general workshop instructions: Welding symbols.

6 Erection of precipitator housing

See FLS erection manual for electrostatic precipitator.

Type F and FM:

Crane to be disengaged when the gantry is absolutely plumb.

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