Electrostatic Precipitator: Insulation - Type E, EM, F and FM

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Electrostatic precipitator
Insulation – Type E, EM, F and FM.
General description
Approved date: 27-Apr-2015
Created by: VIKD-IN

Approved by: DSI-IN
Doc. No.: 70023143 – 2.1

70023143 – 2.0
List of contents:
1. Introduction 4
2. Scope of supply 4
2.1 Basic Engineering 4
2.2 Detail Engineering – Partial 4
2.3 Detail Engineering – Full 5
2.4 Complete Engineering 5
3. Extent of insulation 5
4. Storage 5
5. Base construction 5
6. Cladding 6
7. External equipment 6
8. Materials 6
8.1 Side walls, upper and lower end wall, bottom hoppers, inlet and outlet ducts 6
8.2 Precipitator columns (type F only) 6
8.3 Precipitator roof with sectional steel-supported covering sheets 7
9. Execution 7
9.1 Base Construction, insulation and covering – Erection flow. 7
9.2 Insulation of precipitator surfaces with the exception of roof and
column – 8
9.2.1 Insulation Covering 9
9.2.2 Details. 10
9.3 Insulation of precipitator roof 11
9.3.1 Precipitator roof with sectional iron-supported covering plates 11
9.3.2 Covering 11
9.3.3 Alternative to sectional iron-supported covering plates 11
9.3.4 Leads-in in covering plates 11
9.4 Insulation of columns for Type - F 12
9.4.1 Insulation 12
9.4.2 Covering 12
10. Description of insulation of Flat bottom hopper precipitator (Type – E) 14
10.1 General 14
10.2 Extent of insulation 14
10.3 Materials 14
10.4 Insulation of the lower horizontal hopper 14
10.4.1 Insulation 15
10.4.2 Covering 15
11. Text for enclosure 16
The information transmitted by this document is the proprietary and confidential property of FLSmidth
and may not be duplicated, disclosed or utilized without written consent from FLSmidth. 2/56
70023143 – 2.0
Enclosures / section descriptions
Types of insulation 70023143 - 01, 02, 03

Types of insulation 70023143-04
Assembly sketch type E 70023143-05
Assembly sketch type F 70023143-06
Guidelines Sketches for Insulating different areas.

Covering – Expansion zones 70023143-08
Covering – Construction guidance 70023143-09
Covering – Design base construction 70023143-10
Covering – Insulation construction 70023143-11
Covering – Trapezoid plate cladding of side wall 70023143-12
Covering – Plane plate cladding of bottom hopper and side wall 70023143-13
Covering – Erection of Steel supported roof 70023143-14
Covering – Erection of Steel supported roof 70023143-15
Covering – Insulator box 70023143-A

Covering – Old type inspection door 70023143-B
Covering – Insulation plug for inspection door for precipitator casing 70023143-C
and bottom hopper
Covering – Inspection door for precipitator casing and bottom hopper 70023143-D
Covering – Transition on inlet duct 70023143-E
Covering – Edge of bottom hopper 70023143-F
Covering – Edge on precipitator casing 70023143-G
Covering – At and around the bottom of the precipitator column 70023143-H
Covering – Between precipitator wall and bottom hopper 70023143-I
Covering – Longitudinal precipitator duct with thermal zone 70023143-J
Covering – Drive station at bottom hopper / drag chain 70023143-K
Covering – Transition at inlet duct 70023143-L
Covering – Between top of outlet duct and side of precipitator 70023143-M
Covering - Top of outlet duct 70023143-N
Covering – Edge of inlet Duct, T –inlet 70023143-S
Covering – Longitudinal double precipitator hopper 70023143-V
Covering – Relief between bottom hoppers 70023143-W
”Tension Member” – Type E and F
Covering – Pyramid precipitator duct with thermal zone 70023143-X
Covering – Lead-in in outer cladding 70023143-Y
Sketches for Type F

Covering – Inlet Duct and Roof 70023143-Q
Covering – Outlet Duct and Roof 70023143-R
Covering – Column and top of column 70023143-T
Covering – Column bottom and wind relief 70023143-U
Covering – Drive station 70023143-P
Covering – Drive station 70023143-Pa
Sketches for insulating Flat bottom hopper Type E

Covering and insulation of flat bottom hopper see along 70023143-1a
gas direction
Covering and insulation of flat bottom hopper see across 70023143-1b
gas direction with heating element
70023143 – 2.0
1 Introduction
All information in this Instruction Manual is only intended as a guide and as minimum standards
for the insulation work. The supplier has the responsibility to see to it that all local demands are
complied with and all standards are observed. It also rests with the supplier to dimension
supports, plate thicknesses, sizes of pop rivets, self tapping screws, etc.
The object of insulating an electrostatic precipitator is to ensure that the hot flue gases will not
be cooled to the dew point during passage through the precipitator as well as the personal
security during operation of the plant.
Such cooling would result in precipitation of liquid followed by corrosion, accumulation of dust,
and electric flash-over between the electrodes. This may reduce the nominal output of the
machine.
Insulation ensures uniform heating of the precipitator housing, and hence large thermal stresses
are avoided which otherwise might cause deformations.
Deformations may change the distance between electrode units and thus cause a reduction of
the precipitator voltage and the efficiency.
The insulation consists of mineral wool which is covered with a weather-resistant coating
mounted flexibly so as to take up thermal expansion.
The insulation work may advantageously be entrusted to a specialist firm which can give advice
as regards costs of materials and/or costs of work.
2 Scope of supply
2.1 Basic Engineering
In Basic Engineering, FLS Airtech provides only the specification, the supply of insulation
material and mounting accessories and erection is done by the client.
The specifications provided for the client are following.
 Insulation part list

 Standard Insulation drawing
 Standard Insulation manual
2.2 Detail Engineering – Partial
In Detail Engineering Partial –FLS Airtech will supply only the Insulation and cladding
material, other items like mounting accessories supply and Erection is by client. Client has
to take care of Mounting design and calculations for it and also Erection.
The below documents will be forwarded to client.
 Insulation part list with Bill of material ( Only for insulation and cladding
material )
 Standard insulation drawing
 Standard insulation manual
70023143 – 2.0
2.3 Detail Engineering – Full
In Detail Engineering Full –FLS Airtech will supply the Insulation and cladding material and
other items including mounting accessories and Erection is by client. Client has to take care
of Erection.
 Insulation part list with Bill of material ( For Insulation, Cladding and Mounting
Accessories)
 General Erection drawing
 Standard Insulation Manual
2.4 Complete Engineering
In Complete Engineering –FLS Airtech will supply the Insulation and cladding material and
other items including mounting accessories and Erection is also by FLS Airtech.
 Insulation part list with Bill of material ( For Insulation, Cladding and Mounting
Accessories)
 General Erection drawing
 Standard Insulation Manual
3 Extent of insulation
All the external surfaces of the precipitator casing as well as inlet and outlet ducts must be
insulated, including the areas in which supports are fastened. The drive station and tail station for
the drag chain or the screw conveyor should be insulated. Rotary Airlock, Rapping Drive units,
Insulator compartments and branch boxes must also be insulated. Purge air pipes must be insulated,
if heater unit is used.
4 Storage
The insulation material must be stored on a dry support where it is not exposed to water or
other kinds of moisture which may enter the material. The material must also be protected
during the mounting work and when the insulation has been mounted and the covering work has
not yet been finished.
5 Base construction
In order to ensure a tight and durable cover of the precipitator for many years it is necessary to
carry out a thorough installation of the base construction.
The design of the base construction must be carried out according to the same principles on
inlet, outlet, precipitator casing and bottom hoppers.
This applies also to the quality of the design of the base construction before mounting of
insulation material and cover plates.
70023143 – 2.0
6 Cladding
The insulation must be provided with a weather-proof covering, e.g. aluminum or galvanised
sheets, either plane or corrugated.
All sheet work must be rain-proof. This is particularly necessary at inspection doors and lead-
insulator where the rain-proofing must overlap and seal effectively.
Fastening steel must be properly corrosion-proofed so as to avoid that any condensate on the
inside of the covering sheet is not discoloured by rust, which seeps out causing the covering
sheets to be discoloured.
Cladding sheets must be fastened by means of self-tapping screws in case there is a backing
plate and use Pop rivets if there is no backing plate, for cases like joining two plane cladding
plates at the corner covering of ESP. The material used for screw and rivet should be same as
the cladding metal in order to avoid corrosion.
7 External equipment
In order to avoid conductors of cold, all small external equipment such as cable trays, pipe
clamps for small pipes, soil pipes etc. must be fastened to the external cladding with screws,
taking care not to interfere with the sliding joints in the sheets.
8 Materials
Construction of insulation
Encl. 70023143 - 01, 70023143 - 02 and 70023143 – 03 show the types of insulation used for
insulating electrostatic precipitators and encl. 70023143 – 04the insulation type description is
explained.
For designation of types, see dimension sketch together with text sheet or order.
8.1 Side walls, upper and lower end wall, bottom hoppers, inlet and outlet
ducts
The following types of insulation are used, unless something else is specified in the
order.
For precipitator temperatures up to 400°C use:
U-100T-A1, U-150C-A1, U-200C-A1 or U-300C-A1.
8.2 Precipitator columns (type F only)

200 mm insulation is normally used on the columns, unless something else is
specified in the order.
For precipitator temperatures up to 400°C: U-200H-A1, U-200C-A1 or U-200T-A1 .
For covering, however, use, usually plane aluminum sheet instead of corrugated
sheet.
70023143 – 2.0
8.3 Precipitator roof with sectional steel-supported covering sheets

Use the same insulation as mentioned in sub-section 8.1, however, Special
covering arrangement with 2° inclination to be carried out, the design and
engineering done along with Equipment.
9 Execution
Important !!
Timber or other inflammable material must not be used as support for insulation. All materials
used must be heat-resistant and free from imperfection such as cracks, flaws and inclusion.
If different materials are used for construction of the external cladding, for instance aluminium
plate, galvanized plate, rough steel, or other varied materials which can cause corrosion by
contact, it is important to separate these materials by means of tape (10) or the like in order to
avoid contact corrosion.
9.1 Base Construction, insulation and covering – Erection flow.

The design and actual of the base construction is very important for correct execution of
the insulation work as well as for the appearance of the final product.
The below explanation is a step-by-step guidance, from side wall to outer cladding. See
encl. 70023143 – 09 and 70023143 - 10 which show how a base construction should be
designed and construction.
To avoid thermal bridge between the filter side and the outer cladding the distance angle
iron (03) shall always be carried out with insulation pad. The Insulation pad shall be of
Ceramic fibre (for example “KAOWOOL- high strength paper or similar).
On encl. 70023143 – 10 Insulation constructions is shown.
A - Mounting of Distance angle iron with insulation pad (03) perpendicular to the
stiffening steel of the precipitator wall, length of angle irons is adapted before
welding, and welding of bracings (04).
B – Then the first layer of insulation wool material is mounted (15).
C – Mounting of locking plate (05) on first layer of the insulation material.
D – Mounting of next layer of insulation wool material.
E – Mounting of locking plate (05) on next layer of insulation material and bend the
bracings (04) projecting out of insulation wool (15).
F – The insulation material must be pressed to enable mounting of the Cladding support
angle iron (02) which is fixed to one of the ends with the calculated distance to the
side wall of the precipitator; please ensure sufficient space to the insulation material,
especially near to stiffening irons on precipitator wall.
G – It is now possible to mount the outer cladding sheet on angle irons (02).
9.2 Insulation of precipitator surfaces with the exception of roof and

column – Type F
The stiffening irons of the precipitator must be covered by the full insulation thickness on
the precipitator side walls and the upper and lower end walls(encl. 70023143 – 10).
70023143 – 2.0
The insulation thickness over the stiffening irons on bottom hopper, inlet and outlet ducts
must be as stated below.
a. If the height of the stiffening iron is equal or smaller than 2/3 of the insulation
thickness, insulate without additional thickness over the stiffening iron.
b. If the height is bigger than 2/3 of the insulation thickness, insulate with additional
insulation on the stiffening iron.
The thickness of the additional insulation must be minimum 1/3 of the insulation,
however the insulation thickness must correspond to the thickness of a standard
insulation mat.
Before the mineral wool is placed on the plate side, ties for insulation and supporting
irons for cover plates must be welded on. It is important that the braces are approx. 10
mm shorter than the insulation thickness in order to avoid unintended contact with the
outer cladding. If longer ties have been chosen, they must be bended before mounting of
outer cladding.
Note that there should be no insulation in the hollow space (encl. 70023143 - 10, Figure
A) between plate side and stiffening iron flange, because this would prevent thermal
radiation and hence cause thermal bending of the stiffening iron.
Now, place the first layer of mineral wool over the fixing irons and lock it against the
precipitator plate side by means of locking plates (05). (Encl. 70023143 - 09, C).
Then, place the second layer on top of the first mineral wool layer (encl. 70023143 – 09,
D). Layer joints must not coincide (bond) (Encl. 70023143 - 11).
When the second layer mineral wool is placed over the ties, it must be locked by means
of locking plate (05). Both are thus fixed by means of locking plate (encl. 70023143 - 09,
E).
The outer layer is retained by stretching galvanized wire between the ties and
bending the extreme ends of the ties.
It is very important that the insulation material is packed, which means that the
insulation material is squeezed (approx. 2 mm per meter) in order to avoid cracks in
insulation when the plant is set in operation.
Then, place the covering plates (14) on the last mineral wool layer, (encl. 70023143 - 09,
G) and bolt them to the angle iron. (See encl. 70023143 – 12, 70023143 – 10, B)
9.2.1 Insulation Covering

Provide the insulation with weather-resistant covering plates, either plane or
corrugated.
Plate size is according to the supplier and in accordance with the precipitator in
question.
Covering plates and insulation can be fastened using several methods. Below,
two methods for insulating electrostatic precipitators are described.
70023143 – 2.0
Method I – Corrugated plate covering

See encl. 70023143 - 08, 70023143 - 09, 70023143 – 10, 70023143 - 12
In general, cladding iron (02) is welded to the precipitator stiffening irons by

means of legs which are also made from distance bar (03); distance between
two legs must be approx. 500 mm (d2). In order to avoid tensions in the
cladding iron (02) do not weld it together in longitudinal direction, and ensure
that there is minimum 10 mm (d) air between the ends of the cladding iron. The
cladding iron must be disconnected for every 1500 millimetre (d3) due to
thermal expansion. The distance (d1) must not exceed 150 mm.
In some instances where it is not possible to mount the distance bar (03) on the
precipitators stiffening iron it may, however, be required to weld the legs (02)
directly on to the precipitator wall. For instance in the expansion zone where the
stiffening irons of the precipitator have not been mounted appropriately see encl
70023143 - 10, A.
The insulation is fixed by means of ties minimum ø 4 mm (04), which must be

welded to the precipitator wall, using minimum 5 per m2 (5-8 per m²).
Corrugated plates are fixed by means of Self-tapping screws with washer and
gasket. Expansions in the underlay constructions are absorbed in the waves in
the plates. Considering the expansion joint, the fastening of corrugated plates
near splitting (d) of the cladding iron (02) is to be avoided.
At horizontal plate joints (expansion joints) the distance from the outer plate
edge to the first row of angle irons on the top plate must not exceed 250 mm
(d4). Correspondingly, the distance from the inner plate edge to the first row of
angle irons on the bottom plate must not exceed 250 mm (d6). In this way, the
cross-overlapping of the plates will be approx. 200 mm (d5). Similarly for
vertical plate joints, it is important to provide cross-overlapping to avoid
deformation of cladding due to thermal expansion (thermal expansion approx
5mm/m). See encl. 70023143 - 08.
Because of the expansion, the cross-overlapping (d5) must not be bolted or

riveted together. Rivet the vertical plate joints together with a distance between
the rivets of approx. 300 mm, since expansion is absorbed by the corrugation of
the plates.
Method II – Plane plate covering

See encl. 70023143 - 13.
Cladding angle irons (02) with welded-on legs (03) are welded on to the
stiffening irons of the precipitator. Base construction must be made as described
under method I, however, with extra stiffening irons which are mounted so that
each cover plate can be fixed at the joints and on each side of the expansion
joints.
For fixing of the insulation, ties ø 4 mm are used as mentioned under method I.
The expansion of plane face covering is taken up in the S-joints (s), and this is
why the sheets must not be bolted or riveted together here. See encl. 70023143
– 08.
70023143 – 2.0
9.2.2 Details.
Pyramid bottom hoppers (encl. 70023143 - X, 70023143 - F) insulation is

done by welding ties and angle iron (03) directly on the hopper wall but in some
cases insulation can be carried out with a heating zone which is formed by
welding-on a 1 mm panel (09) which is welded on to the stiffening irons of the
bottom hopper so that a cavity is created. The outside of the steel sheet is
insulated in the usual manner by welding-on ties and angle iron (03). As far as
possible, spacer irons should only be welded on opposite the stiffening irons of
the bottom hopper.
Longitudinal bottom hoppers (encl. 70023143 - J) can be provided with

heating zone and are basically insulated as described for pyramid bottom
hoppers. (encl. 70023143 - X).
The bottom of the bottom hopper is normally covered by a casing which is either
fastened to a plane plate or to the covering sheets with pop rivets. The
construction must normally be adapted during erection. The bottom hopper is
normally provided with a bottom hatch. The covering on same must be
removable and therefore be provided with snap-action locks.
Relief on bottom hoppers (Type E & F)- Tension member: (encl. 70023143
- W)
If the precipitator is of a type/width with two (or more) bottom hoppers placed
across of the gas direction there will, to relief the precipitator construction, be
mounted in pairs between the bottom hoppers “tension members”. These
tension members shall also be insulated in order to avoid conductors of cold.
The thickness of insulation must be the same as on the bottom hopper itself and
must be mounted as pipe insulation.
Corner Covering
The edges of the walls, hopper and inlet outlet ducts are covered using corner
covering piece (14, 16); (see encl 70023143 - G, 70023143 - F, 70023143 – L,
70023143 - M, 70023143 - N, 70023143 – E, 70023143 - I, 70023143 – H).
Inspection doors
(Encl. 70023143 – C, 70023143 – D) shows the insulation plug for inspection
door on precipitator casing and bottom hopper etc. (t = nominal insulation
thickness, h = height, w = width).
The insulation material must be packed in heat-resistant glass fibre cloth (23) or
other suitable material, the front is provided with a handle as shown in the
sketch. The same type/design of insulation must preferably be used for the
doors in the bottom hoppers. So as not to create any conductors of cold, always
mount insulations rings (23) between spacer iron (03) and clamp for cladding
.In order to deflect rainwater from the top of the door drip (20) is used.
Insulator chambers
Insulator chambers are insulated with 100 mm insulation (15), if the order does
not state something else. For type F the cover is normally pre-insulated from
70023143 – 2.0
workshop, and only the sides must be insulated. The sides must be insulated all
way down to precipitator roof.
Wind bracing
If the precipitator is provided with “wind bracing”, this is a pipe that support
column between the pendular supports. These need to be insulated together
with the precipitator side and the bottom hopper if it is possible with the entire
insulation.
Drive Station
The drive station is insulated in similar way like precipitator wall using braces or
ties(04) and angle iron and for the purpose of inspection a door (hatch 22) and
a steel frame (21) is provided, see encl 70023143 - K.
9.3 Insulation of precipitator roof
9.3.1 Precipitator roof with sectional iron-supported covering plates

The sectional iron support is mounted first which can be done in different ways.
The construction may be completed as shown on encl. 70023143 -14, 15. A
through-going beam is placed on the longitudinal centre line of the precipitator.
Then weld beams at 2° inclination to this beam over the centre line of each portal
and at the end walls of the precipitator. The through-going beam is fastened by
only welding opposite the fixed bearing of the precipitator. Weld on angle irons
or channel irons between the beams and over the portals so as to stiffen the
covering plates. In the arrangement shown, the thermal expansion may e.g. be
taken up by flat iron bow and bolt, sub-section B-B, encl. 70023143 – 14,15.
The iron support must be dimensioned for the load the roof may be subjected to,
e.g. loads from persons, snow, or dust. FLSmidth Airtech standard load 2 kN/m2.
When the iron support has been mounted, the roof is insulated with the same
type of insulation as used for the precipitator side walls. The insulation may e.g.
be fixed by means of galvanized wire.
9.3.2 Covering
The covering plates are placed in rows on the stiffening irons and fastened by
means of bows which are welded to the bent-up edge of the plates. The bows
must have a hold on the stiffening irons.
9.3.3 Alternative to sectional iron-supported covering plates

The covering plates may either be provided with stiffening steel from workshop
or be welded to the beam support over the portals, or they may be supplied as
standard plates so that the roof is constructed during mounting.
9.3.4 Leads-in in covering plates
Normally there will only be lead-ins for insulator chambers, however, the
following lead-ins may also be seen: Drive stations for discharge system,
supports for rectifiers, and supports for pipes on the precipitator roof. It is
important to provide coverings around all lead-ins. See for instance section B-B
on encl. 70023143 - 14.
70023143 – 2.0
9.4 Insulation of columns for Type - F

The precipitator columns may be insulated in different ways. The methods used by
FLSmidth are described below.
Tack-weld column shelve (26) of 1 mm steel sheet to the web plate and flanges of the
columns at a mutual distance of approx. 2 m in the longitudinal direction of the column
(see encl. 70023143 - T). The column shelves may also be made of rigid insulation
sheets which can be fixed by means of fixing irons
The column shelves serve to prevent chimney draught effect in the column.
Prior to mounting column casing (27), insulate the triangle cavity at column top and
column bottom with wire gauze batts or fire batts, if the temperature exceeds
200°C. If the temperature is below 200°C, use mineral wool without wire gauze. Fill
the cavities entirely. The insulation may be fixed by means of ties.
Tack-weld column casings (27) of 2 mm steel sheet to the column flanges. The
column casing width must correspond to the section height less one flange
thickness. The column casings serve to ensure temperature equalization between
the internal and the external column flange and to prevent the insulating material
from entering cavity.
Omit the column casings when using rigid insulation sheets e.g. fire batts. Fasten
the insulation sheets by means of ties.
The column casings may also be omitted when using sire gauze between the column
flanges. Weld the wire gauze to the column flanges. In this instance the insulation
consists of mineral wool batts with and without wire gauze, depending on the
temperature.
Angle irons (02) with legs (03) are welded horizontally on to the external flange of
the column at a distance corresponding to the construction used on the side wall.
The base construction may also be erected vertically; in that case, the angle irons
must be disconnected every third meter due to thermal expansion.
9.4.1 Insulation
Insulate the column as described in sub-section 8.2.
When using wire gauze batts (or fire batts) same must be placed innermost and
be fastened on the bars by means of locking plates or galvanized wire.
Place the external batts so that the joints between the batts of the internal
layer do not coincide with the joints of the external layer.
9.4.2 Covering
After completion of the insulation, it is normal to fit an external column casing

(26) of 1 mm plane, weather-resistant aluminium sheet see encl. 70023143 -
T. The column casing is fastened by means of pop rivets to the angle irons on
the side wall and to the vertical/ horizontal angle iron on the external flanges of
the column. The casing must be placed in same level as the expansion zone for
the covering plates of the side walls, and the overlapping must be minimum
70023143 – 2.0
100mm. Rivet or bolt the column casings together, except in the expansion
zone.
Corrugated sheets (13), which cover the precipitator wall, overlap the column
casing flange at the fixing bows on the side wall, see encl. 70023143 - T. The
corrugated sheets may be fastened to the column casing flanges by means of
tubular rivets, however, not in the expansion zone.
Finish the column insulation at the top with a column cap which is riveted to the
last column sheet plate. see encl. 70023143 - T.
Finish the insulation at the column base with an ordinary column sheet plate
which is to be adapted during mounting, if the precipitator is mounted on roller
bearings. The bottom beam must normally be covered by means of plane
aluminium sheet during mounting see encl. 70023143 - U.
If the precipitator is mounted with pendular support, covering must be provided
below the baseplate of the column when mounting, see see encl. 70023143 - U.
Adapt the lower column casing during mounting.
If the precipitator is constructed with wind relieves – “windbracing” – between
supports, and then these must be insulated together with the precipitator side
and the bottom hopper, as far as possible with the full insulation thickness. See
encl. 70023143 – U.
70023143 – 2.0
10 Description of insulation of Flat bottom hopper precipitator

(Type – E)
10.1 General
Principle of insulation of a flat bottom hopper precipitator is same as a standard type-E
precipitator. The lower flat bottom hopper frame is special for type-E of the flat bottom
precipitator and is described in the following. All information in this Instruction Manual is
only intended as guide and as minimum standards for the insulation work. The supplier has
the responsibility to see to it that all local demands are complied with and all standards are
observed. It also rests with the supplier to dimension supports, plate thicknesses, sizes of
pop rivets, screws, etc.
10.2 Extent of insulation

The lower flat bottom hopper beam which is the bottom of the filter frame of a horizontal
hopper precipitator is to be insulated.
10.3 Materials
As a standard, 200 mm insulation is used on the beams if nothing else is informed in the
order.
For filter temperatures upto 400°C use: U-130C-A1, U-150C-A1, U-200C-A1, U-250C-A1 or
U-300C-A1.
10.4 Insulation of the lower horizontal hopper beam

The lower flat bottom hopper beam can be insulated in more than one way. The methods
that FLSmidth Airtech uses is described in the following.
Before the inner column cap (17) is mounted, insulate the triangle hollow space in the
column bottom with wire cloth batts or with fire batts when the temperature exceed 200°C.
If the temperature below 200°C use batts without wire cloths. The hollow spaces must be
filled out. The insulation can, if necessary, be held on with ties.
The column caps (17) in 2 mm steel plate is tack welded to the columns flanges. The width
of the column cap must correspond to the profile height minus flange thickness. The column
caps will ensure the temperature equalising between the inner and the outer column flange,
and prevent the insulation material in penetrating into the hollow space.
The column caps can be left out if stiff insulation plates are used such as fire batts. The
Insulation plates are fastened with ties or similar.
The column caps can be left out if there are used wire cloths between the columns flanges.
The wire cloths must be welded to the columns flanges. The insulation consists, in this case,
of mineral wool batts with and without wire cloths depending of the temperature.
Angle iron (02) with legs (03) is welded horizontal on the columns outer flange with a
distance equalling to the construction that is used on the side wall. It is also possible to
70023143 – 2.0
mount the underlayer construction vertical; in that case the angle iron must be broken for
every three meters due to the heat expansion.
10.4.1 Insulation
The column must be insulated as described in section 9.
If the wire cloth batts (or fire batts) is used they must be placed at the inner and
fastened over the ties with lock plates or galvanized thread.
The outer batts must be placed so that the assembly between the batts in the
inner layer is not the same as the assembly in the outer layer.
10.4.2 Covering
When the insulation is carried out, place an outer column casing (26) (normally
made of 1 mm weather consistent plane plate. The column cap is pop riveted to
the angle iron on the bottom wall and to the vertical / horizontal angle iron on the
bottom beam outer flange. The caps are made with an overlap of 50 – 100 mm. In
the expansion zone the assemblies should, if possible, be placed at the same level
as the expansion zone for the bottom walls covering plates, the overlap must be at
least 100 mm. The column caps must be riveted or screwed together, except in the
expansion zone.
The corrugated plate (13) that covers the filter bottom wall overlaps the column
caps flange at the side coverings underlay construction, se enclosure 70023143 –
1a and 70023143 – 1b. The plates can be riveted together with the column cap
flanges, except in the expansion zone.
The column insulation is completed at the top with a cross column hat that
normally is fitted during the mounting, this is riveted on to the last column cap.
At the bottom of the column foot complete the covering with an ordinary column
cap that is adjusted during mounting. There must be, if possible, unobstructed
movement at the precipitator support, if this is mounted on roller bearings. The
bottom beam must normally be covered as the rest of the beam with a plane plate
which is shaped during mounting.
When the filter is mounted with pendular support, there must be fabricated a cover
under the beam during the mounting. The bottom beam cap is made during
mounting (17).
70023143 – 2.0
11 Text for enclosure
1 Precipitator wall
2 Cladding support, Galvanized angle
iron, 30x30x3 mm
21 Steel frame
3 Distance angle iron, 30x30x3 mm
22 Insulating hatch
with Insulation pad
23 Glass fibre cloth / Insulation Pad
4 Bracing or ties
24 Door casing
5 Lock
25 Stitching
6 Spacer iron for Heating zone
26 External column casing, plane
7 Self-tapping screws ø4,8 mm
cladding
8 Pop rivet TAP 58
27 Internal column casing, plane
9 1mm Panel, Barrier plate for cladding
Heating zone
28 Stanchion rack in casing column
10 Glass tape (for F type)
11 Steel plate (chequer plate) 29 Heating element on Hopper
12 Outer cladding - Plane
13 Outer cladding - Corrugated
14 Corner covering
15 Insulation wool
16 Angle section / transition piece
(Corner covering)
17 Column cap, 1mm panel
18 Rain guard, steel plate
19 Roof gutter
20 Gutter bracket
---o0o---
70023143 – 2.0
Type of Insulation on ESP
70023143 - 01
70023143 – 2.0
70023143 - 02
70023143 – 2.0
70023143 - 03
70023143 – 2.0
Designations:
Protection
1 = 0,70 mm plate with 19 mm corrugation
2 = 0.75 mm plate with small corrugation
3 = 0.90 or 1.00 mm plane plate
4 = 3.00 mm tear plate or plane plate
5 = 5.00 tear plate or plane plate
N – no protection cover
А - aluminium cover (alloy 3S 1/1 H)
S - Galvanised steel cover
H = ordinary mats (λ10=0.037 W/м°C)

T = wire mats (λ10=0.037 W/m°C)
P = lamella mats (2 layer of equal thickness)
J = industrial mats (λ10 = 0.033 W/m°C,
density 100-110 kg/м3)
F = fire mats (λ10 = 0.033 W/m°C, density
100-110 кg/m3)
В = combination of industrial and fire mats

C = combination of ordinary and wire mats
Thickness
Outer
70023143 - 04
70023143 – 2.0
Assembly Sketch Type E
70023143 - 05
70023143 – 2.0
Assembly Sketch Type F
70023143 - 06
70023143 – 2.0
Covering – Expansion zones
70023143 - 08
70023143 – 2.0
Covering – Construction step by step procedure
70023143 - 09
70023143 – 2.0
Covering – Construction principle
70023143 - 10
70023143 – 2.0
Covering – Insulation construction
70023143 - 11
70023143 – 2.0
Covering – Trapezoid plate cladding of side wall
70023143 - 12
70023143 – 2.0
Covering – Plane plate cladding of bottom hopper and side wall
70023143 - 13
70023143 – 2.0
Covering – Erection of Steel supported roof
70023143 - 14
70023143 – 2.0
Covering – Insulator box
70023143 - A
70023143 – 2.0
Covering – Old type inspection door
70023143 – B
70023143 – 2.0
Covering – Insulation plug for inspection door inspection door.
70023143 - C
70023143 – 2.0
Covering – Inspection door for precipitator casing and bottom hopper
70023143 - D
70023143 – 2.0
Covering – Transition on inlet duct
70023143 - E
70023143 – 2.0
Covering – Edge of bottom hopper
70023143 - F
70023143 – 2.0
Covering – Edge on precipitator casing
70023143 - G
70023143 – 2.0
Covering – At and around the bottom of the precipitator column
70023143 - H
70023143 – 2.0
Covering – Between precipitator wall and bottom hopper
70023143 - I
70023143 – 2.0
Covering – Longitudinal precipitator duct with thermal zone
70023143 - J
70023143 – 2.0
Covering – Drive station at bottom hopper / drag chain
70023143 - K
70023143 – 2.0
Covering – Transition at inlet duct
70023143 - L
70023143 – 2.0
Covering – Between top of outlet duct and side of precipitator
70023143 - M
70023143 – 2.0
Covering - Top of outlet duct
70023143 - N
70023143 – 2.0
Covering – Edge of inlet Duct, T –inlet
70023143 - S
70023143 – 2.0
Covering – Longitudinal double precipitator hopper
70023143 - V
70023143 – 2.0
Covering – Relief between bottom hoppers Type E and F
70023143 - W
70023143 – 2.0
Covering – Pyramid precipitator duct with thermal zone
70023143 - X
70023143 – 2.0
Covering – Lead-in in outer cladding
70023143 - Y
70023143 – 2.0
Covering – Inlet Duct and Roof – Type F
70023143 - Q
70023143 – 2.0
Covering – Outlet Duct and Roof – Type F
70023143 - R
70023143 – 2.0
Covering – Column and top of column – Type F
70023143 - T
70023143 – 2.0
Covering – Column bottom and wind relief – Type F
70023143 - U
70023143 – 2.0
Covering – Drive station – Type F
70023143 - P
70023143 – 2.0
Covering – Drive station – Type F
70023143 - Pa
70023143 – 2.0
Covering and insulation of flat bottom hopper seen along gas direction
70023143 – 1a
70023143 – 2.0
Covering and insulation of flat bottom hopper seen across gas direction with heating element
70023143 – 1b

Electrostatic Precipitator: Insulation - Type E, EM, F and FM

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Electrostatic Precipitator: Insulation - Type E, EM, F and FM

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Approved date: 27-Apr-2015

Created by: VIKD-IN

Doc. No.: 70023143 – 2.1

Enclosures / section descriptions

Types of insulation 70023143 - 01, 02, 03

Guidelines Sketches for Insulating different areas.

Covering – Insulator box 70023143-A

Sketches for Type F

Sketches for insulating Flat bottom hopper Type E

The specifications provided for the client are following.

 Insulation part list

2.2 Detail Engineering – Partial

The below documents will be forwarded to client.

2.3 Detail Engineering – Full

The below documents will be forwarded to client.

2.4 Complete Engineering

The below documents will be forwarded to client.

8.2 Precipitator columns (type F only)

8.3 Precipitator roof with sectional steel-supported covering sheets

9.1 Base Construction, insulation and covering – Erection flow.

9.2 Insulation of precipitator surfaces with the exception of roof and

9.2.1 Insulation Covering

Method I – Corrugated plate covering

In general, cladding iron (02) is welded to the precipitator stiffening irons by

The insulation is fixed by means of ties minimum ø 4 mm (04), which must be

Because of the expansion, the cross-overlapping (d5) must not be bolted or

Method II – Plane plate covering

Pyramid bottom hoppers (encl. 70023143 - X, 70023143 - F) insulation is

Longitudinal bottom hoppers (encl. 70023143 - J) can be provided with

9.3 Insulation of precipitator roof

9.3.1 Precipitator roof with sectional iron-supported covering plates

9.3.3 Alternative to sectional iron-supported covering plates

9.4 Insulation of columns for Type - F

After completion of the insulation, it is normal to fit an external column casing

10 Description of insulation of Flat bottom hopper precipitator

10.2 Extent of insulation

10.4 Insulation of the lower horizontal hopper beam

11 Text for enclosure

Type of Insulation on ESP

Type of Insulation on ESP

Type of Insulation on ESP

H = ordinary mats (λ10=0.037 W/м°C)

В = combination of industrial and fire mats

Assembly Sketch Type E

Assembly Sketch Type F

Covering – Expansion zones

Covering – Construction step by step procedure

Covering – Construction principle

Covering – Insulation construction

Covering – Trapezoid plate cladding of side wall

Covering – Plane plate cladding of bottom hopper and side wall

Covering – Erection of Steel supported roof

Covering – Transition on inlet duct

Covering – Edge of bottom hopper

Covering – Between precipitator wall and bottom hopper

Covering – Transition at inlet duct

Covering – Between top of outlet duct and side of precipitator

Covering - Top of outlet duct

Covering – Edge of inlet Duct, T –inlet

Covering – Longitudinal double precipitator hopper

Covering – Lead-in in outer cladding

Covering – Outlet Duct and Roof – Type F