Doc. No.
MAINTENANCE STANDARD REPORT Issue Date xx xx xxxx
Revision No. 00
Title:
DRY CLEANING AND INSPECTION ESP UNIT #2
Major Schedule For Dry Cleaning and Inspection ESP Unit #2
No. Date Description Detail Description Remarks
1 Day 1 AEP team arrive to site 1. Team manpower arrived at Babelan site
2. Safety training
2 Day 2 Preparation 1. Tools and machine arrived and shift to ESP #2
2. Open all manhole at side and top of ESP and
open all insulator cone ceramic box cover
3. Connection for air compressor pipes
4. Connection for all lighting and fans blower
5. Install scaffolding for hopper and open
expansion Joint at hopper outlet flange
6. Alignment the cover for hopper
3 Day 3 Cleaning For First Field Cleaning inside of ESP
4 Day 4 Cleaning First and Second Cleaning inside of ESP
Field
5 Day 5 Cleaning Cleaning For Second Field Cleaning inside of ESP
6 Day 6 Cleaning For Third Field Cleaning inside of ESP
7 Day 7 Cleaning Third and Forth Field Cleaning inside of ESP
8 Day 8 Cleaning For Forth Field Cleaning inside of ESP
9 Day 9 Inspection Hopper 1. Inspection for condition of hopper construction
2. Inspection for condition of ash cleaning
Nozzle 1. Inspection for condition of inlet nozzle
distribution plate
2. Inspection for condition of outlet baffler
channel sheet
Collecting Electrode System 1. Inspection for condition of collecting plate
2. Inspection for condition of collecting plate fixing
condition
3. Inspection for condition collecting plate rapping
hammer alignment
4. Inspection for condition collecting plate rapping
anvil shaft function
Discharge Electrode System 1. Inspection for condition of discharge emitting
wire
2. Inspection for condition of discharge emitting
Frame
3. Inspection for condition of discharge electrode
system rapping hammer alignment
4. Inspection for condition of discharge electrode
system rapping anvil shaft function
5. Inspection for condition of discharge electrode
system rapping force transit insulator and the
insulator heater
6. Inspection for condition of discharge electrode
system hanging bearing insulator
10 Day 10 Inspection Electrical Part 1. Inspection for all heater at hopper and top
(specially the top insulator heaters)
2. Inspection for all rapping motors and gearbox
condition,include emitting rapping / collecting
rapping
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Long Term Maintenance Report [Doc. No. -xx-xxx Rev.00]
Dry Cleaning and Inspection ESP Unit#2
No. Date Description Detail Description Remarks
3. Inspection for all rapping motors and gearbox
condition,include emitting rapping / collecting
rapping
4. Inspection for all transformer condition included
the bushing and connect rod and insulators
5. Test resistance of discharge electrode to
collecting plates
Other Inspection for distance between the collecting
plate and emitting wire , to make sure all distance
is good enough
11 Day 11 Open test and Short test, Megger test on 1. Open test and short test to cross check all
Field, NoLoad test Transformer and control panel are still working
2. Megger to check insulation resistance of
emitting system
12 Day 12 Start up Joint with starting of plant
Friday, 31 May 2019
Install the tarpaulin at ESP’s side to prevent
ashes go further
Prepare to open all manholes
Saturday, 1 June 2019
Open the middle and top position manholes
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Long Term Maintenance Report [Doc. No. -xx-xxx Rev.00]
Dry Cleaning and Inspection ESP Unit#2
Open hopper’s manholes
Clean the manhole’s area
Open the cone ceramic’s housing and ground it
all to discharge electricity charge
Monday, 2 June 2019
Install scaffolding and prepare to dismantle
expansion joint
Dismantle all expansion joint
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Long Term Maintenance Report [Doc. No. -xx-xxx Rev.00]
Dry Cleaning and Inspection ESP Unit#2
Install Cylindrical Tarpaulin to replace the
Expansion Joint, so the ashes will fall down
right to bag of sack
Dry Clean the top position of Field 1
Tuesday, 3 June 2019
Continue the dry clean process in Field 1
Dry clean in Field 2
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Long Term Maintenance Report [Doc. No. -xx-xxx Rev.00]
Dry Cleaning and Inspection ESP Unit#2
Wednesday, 4 June 2019
Dry clean in Field 3 and 4
Sunday, 9 June 2019
Continue dry clean all Fields
Continue clean the cone ceramic housing and
Motor gearbox’s coupling on top area
Monday, 10 June 2019
Continue clean the cone ceramic’s housing and
hammer motor’s casing in the middle area
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Long Term Maintenance Report [Doc. No. -xx-xxx Rev.00]
Dry Cleaning and Inspection ESP Unit#2
Cleaning inside cone ceramic area
Tuesday, 11 June 2019
Re-install pin wheel, shaft and shaft insulator
with new one. This work was carried out
because of the initial plan is to take one set of
them from unit 2 and move to unit 1 first. But
in process there was an accident so the shaft
insulator fell down and broke . As a solution
AEP team decided to provide a new unit of
shaft insulator and re-install
Install all expansion joint
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Long Term Maintenance Report [Doc. No. -xx-xxx Rev.00]
Dry Cleaning and Inspection ESP Unit#2
Wednesday, 12 June 2019
Inspection on inside hopper area
Tag-weld on the male part of pin wheel’s shaft
and its bolt so it won’t be separated
Inspection of distance between the shaft and
cone ceramic
Inspection the distance between Collecting
Plate and Emitting Electrode (Field 1 & Field 2)
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Long Term Maintenance Report [Doc. No. -xx-xxx Rev.00]
Dry Cleaning and Inspection ESP Unit#2
Inspect the distance between Collecting Plate
and Emitting Electrode (Field 3 and Field 4)
Thursday, 13 June 2019
Inspect on collecting plate’s hammer & Anvils
Inspect on collecting plates and emitting
electrodes in Field 1 and Field 2
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Long Term Maintenance Report [Doc. No. -xx-xxx Rev.00]
Dry Cleaning and Inspection ESP Unit#2
Inspect on collecting plates and emitting
electrodes in Field 3 and Field 4
Inspect of inlet screen nozzle distribution plate
Friday, 14 June 2019
Field 1 Megger Resistance Test
Field 2 Megger Resistance Test
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Long Term Maintenance Report [Doc. No. -xx-xxx Rev.00]
Dry Cleaning and Inspection ESP Unit#2
Field 3 Megger Resistance Test
Field 4 Megger Resistance Test
Because of Field 4 result was below 100 MΩ,
AEP team re-check the condition inside of field
4 and re-clean of cone ceramic. After some
time, megger test again and the picture was
result
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Long Term Maintenance Report [Doc. No. -xx-xxx Rev.00]
Dry Cleaning and Inspection ESP Unit#2
Mapping of Emitting Electrodes and Collecting Plates of Field No. 1
WALL 1 2 3 4 5
37
Note :
36
35 Collecting plate in good condition
34
Emitting electrode in good
condition
33
32 Hammer in good condition
31
The condition of Collecting Plate
30 Bending, but based on inspection
the item is still in good condition
for use
29
28 There is joint apart on collecting
Inlet Side
plate item
27
There is damage to the Anvil
26 Hammer, either the loss of bolt or
plate
25
24
23
22
21
20
19
18
17
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Dry Cleaning and Inspection ESP Unit#2
16
15
14
13
12
11
Inlet Side 10
WALL
MANHOLE
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Long Term Maintenance Report [Doc. No. -xx-xxx Rev.00]
Dry Cleaning and Inspection ESP Unit#2
Mapping of Emitting Electrodes and Collecting Plates of Field No. 2
WALL 1 2 3 4 5
37 Note :
36
35 Collecting plate in good condition
34
Emitting electrode in good
condition
33
32 Hammer in good condition
31
The condition of Collecting Plate
30 Bending, but based on inspection
the item is still in good condition
for use
29
28 There is joint apart on collecting
Inlet Side
plate item
27
There is damage to the Anvil
26 Hammer, either the loss of bolt or
plate
25
24
23
22
21
20
19
18
17
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Long Term Maintenance Report [Doc. No. -xx-xxx Rev.00]
Dry Cleaning and Inspection ESP Unit#2
16
15
14
13
12
11
10
WALL
MANHOLE
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Long Term Maintenance Report [Doc. No. -xx-xxx Rev.00]
Dry Cleaning and Inspection ESP Unit#2
Mapping of Emitting Electrodes and Collecting Plates of Field No. 3
WALL 1 2 3 4 5
37 Note :
36
35 Collecting plate in good condition
34
Emitting electrode in good
condition
33
32 Hammer in good condition
31
The condition of Collecting Plate
30 Bending, but based on inspection
the item is still in good condition
for use
29
28 There is joint apart on collecting
Inlet Side
plate item
27
There is damage to the Anvil
26 Hammer, either the loss of bolt or
plate
25
24
23
22
21
20
19
18
17
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Long Term Maintenance Report [Doc. No. -xx-xxx Rev.00]
Dry Cleaning and Inspection ESP Unit#2
16
15
14
13
12
11
10
WALL
MANHOLE
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Long Term Maintenance Report [Doc. No. -xx-xxx Rev.00]
Dry Cleaning and Inspection ESP Unit#2
Mapping of Emitting Electrodes and Collecting Plates of Field No. 4
WALL 1 2 3 4 5
37 Note :
36
35 Collecting plate in good condition
34
Emitting electrode in good
condition
33
32 Hammer in good condition
31
The condition of Collecting Plate
30 Bending, but based on inspection
the item is still in good condition
for use
29
28 There is joint apart on collecting
Inlet Side
plate item
27
There is damage to the Anvil
26 Hammer, either the loss of bolt or
plate
25
24
23
22
21
20
19
18
17
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Long Term Maintenance Report [Doc. No. -xx-xxx Rev.00]
Dry Cleaning and Inspection ESP Unit#2
16
15
14
13
12
11
10
WALL
MANHOLE
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Long Term Maintenance Report [Doc. No. -xx-xxx Rev.00]
Dry Cleaning and Inspection ESP Unit#2
Technical Report Of ESP Unit #2
1. Description The Condition of ESP Unit #2
Most of the outside appearance still good. Painting and welding of all parts still in good condition, all electrical parts
still in good condition, there has no any heaters and thermometers out of working. Function of transformer still at the
correction and rated condition.
2. Small issues from AEP that have been improved by mechanic team
a. Both of collecting plate and emitting system has some of rapping hammers run to out of the correct position. Few
hammers have broken at fixing frame and disappear. It may due to bolt & nuts of the fixing frame has not been
welding-blocked so that after long running nut has been loosened. Mechanical CL team has repaired and installed
new bolts as well as locked with Tag-weld.
b. Some of Rapping anvil plate at collecting plate rapping system has been in loosen condition, and few parts has
disappeared. It happened due to the same reason that the bolt & nut has not been welding-blocked. All bolts and
nuts at rapping system should be better to been welding-blocked. Our CL mechanic team has replaced with new
Anvil Plate in 22 sets, which is replaced according to mapping of field 1 and field 2.
c. Has few pcs collecting plate at unit 2 has been in bend condition. It may happen during the installation time. All
bend collecting plate should be repaired so that can make sure the distance of collecting plate and emitting wire
still be good. Sparking or short will happened at ESP If any of distance between the collecting plate and emitting
wire has been less them 160mm. And will affect to the second voltage and the function of ESP efficiency.
d. Next time overhaul for ESP should check all the rapping shaft fixing sleeve condition. Should repair any broken one
or damaged one so that the anvil function still can be proper.
e. Next time overhaul of ESP also can do the transformer oil filtration and refilling, so that can make sure
transformer keep in good function.
f. ESP unit #2 of dry cleaning and inspection work is started and complete by AEP contractor according to schedule
set on Planner Outage PT. Cikarang Listrindo.
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