How should the electrostatic precipitator of a boiler be inspected, maintained, and operated? What are the requirements?

Operating Instructions for the Maintenance of Electrostatic Precipitators 1 Purpose 1.1 To ensure that the maintenance of electrostatic precipitators meets the requirements regarding maintenance quality standards and civilized production practices. 1.2 For all personnel involved in this project, the quality inspection personnel shall determine the quality assurance procedures that must be followed. 2 Scope of application: Applicable to the maintenance work on the two electrostatic precipitators at Tianjin Datang Panshan Power Generation Co., Ltd. 3 Operating conditions: 3.1 The high-voltage, low-voltage, and control power supplies of the boiler’s electrostatic precipitators must be completely shut off. 3.2 Shut down all manual and electric doors from the gasification fan and air compressor to the electrostatic precipitator, and hang a sign that reads “Personnel are working; operation prohibited”. 3.3 Open the manhole of the electrostatic precipitator and hang a sign stating “Personnel are working; operation prohibited”. 3.4 Team members are aware of the defects in the electrostatic precipitator prior to maintenance. 3.5 Team members are aware of the operating status and hours of use of the electrostatic precipitator. 3.6 Ensure that all specialized tools are complete, in good condition, and reliable for testing. 3.7 Personnel involved in the maintenance work must be familiar with this operation guide, and able to memorize the maintenance tasks, process quality standards, etc. outlined in it. 3.8 Personnel participating in this maintenance project must work with valid safety certificates and be thoroughly familiar with the safety measures specified in this operation guide. 3.9 Prepare all the spare parts and materials required for maintenance. 3.10 Before starting work, assign tasks within the team to all personnel involved in the maintenance, and provide safety and technical briefings. 4 Risk Analysis/Hazard Identification 4.1 Overall hazard identification for the maintenance of electrostatic precipitators: 4.1.1 Personnel involved in the maintenance must receive safety education and technical training to meet the requirements for working on such tasks. 4.1.2 Close all inlet and outlet valves for flue gas, gasification air, and compressed air in the electrostatic precipitator, and attach a warning sign stating “Personnel are working; operation prohibited”. 4.1.3 It is strictly prohibited to damage the equipment and its components during the maintenance of electrostatic precipitators. 4.1.4 The team leader for each operation process shall provide safety briefings and anticipate potential hazards. 4.1.5 The attire of team members must meet the work requirements. 4.1.6 During construction, take measures to prevent falls from heights and injury from falling objects. 4.1.7 Sledgehammers and hand hammers shall be thoroughly inspected before use. 4.1.8 Prevent accidents caused by concurrent construction activities during the building process. 4.1.9 Before starting work, the person in charge shall inform the team members and migrant workers of the safety precautions. 4.1.10 After work is completed, summarize the safety work for that day. 4.1.11 Electric tools must pass inspection before they can be used at work. 4.1.12 When using power tools, a leakage protector must be installed. 4.1.13 When performing welding operations, the distance between the two gas cylinders must meet the requirements specified in the Electrical Safety Work Procedures. 4.1.14 When performing maintenance in an electrostatic precipitator, ventilation should be enhanced before personnel enter. 4.1.15 When working inside an electrostatic precipitator, electric welding and gas welding must not be carried out simultaneously. 4.1.16 During construction inside an electrostatic precipitator, welders should avoid coming into contact with metal parts while welding; they must stand on rubber insulating pads or wear rubber insulating shoes, as well as dry work clothing. 4.1.17 An observer who can see and hear the welder’s work should be stationed outside the electrostatic precipitator, and a switch should be provided to cut off the power supply in response to the welder’s signal. 4.1.18 When using lanterns inside an electrostatic precipitator, the voltage must not exceed 24 volts. The casing of the lantern transformer must be properly grounded, and autotransformers must not be used. 4.1.19 Transformers for walking lights and welding transformers must not be taken into the container. 4.1.20 All personnel working inside the electrostatic precipitator must first learn the *precautions based on the specific nature of their work. There should be no fewer than two workers, with one of them acting as a supervisor outside. The supervisor must stand in a position from where they can see or hear the workers inside the electrostatic precipitator, so as to be able to monitor them at all times; the supervisor is not allowed to take on any other tasks simultaneously. 4.1.21 Before closing the manhole of the electrostatic precipitator, the person in charge of the work must count the personnel and tools, and verify that no one, tools, materials, etc. are left inside the container before closing it. 4.2 Risk analysis during the maintenance of boiler electrostatic precipitators: 4.2.1 All maintenance work on the electrostatic precipitator has been completed; all components have passed inspection, and the interior has been thoroughly cleaned. 4.2.2 All inspections must be passed before installing the gasket for the manhole cover of the electrostatic precipitator. 4.2.3 When reinstalling the various components of the electrostatic precipitator, carefully check to ensure that there are no foreign objects inside. 4.2.4 Carefully check the double numbering of equipment and strictly implement the hazard control cards. 4.2.5 Before starting work each day, the person in charge of the work shall inform the team members and migrant workers of the safety precautions. After the work is completed, a summary of the day’s safety performance shall be made, and any violations committed shall be criticized and addressed; in cases of serious violations, safety training shall be provided. 4.2.6 Coordinate properly during internal maintenance of electrostatic precipitators; electric tools must be equipped with leakage protectors, and the lighting should turn off when no one is present. Protective glasses should be worn when using tools such as electric grinders. 4.2.7 When performing welding operations, the distance between oxygen and acetylene cylinders must comply with the requirements specified in the Power Safety Work Procedures. 4.2.8 Tool belts, safety belts, or fall arrest devices should be used for work at heights. 4.2.9 It is strictly prohibited to stand or pass under the lifted object. 4.2.10 All personnel involved in the project must receive safety technical briefings, so as to clearly understand the construction procedures, tasks at hand, and safety technical requirements. They should have a clear understanding of their roles and responsibilities, and complete the dual-signature procedure. 4.2.11 All construction workers must carry out work in strict accordance with the specified construction procedures, and shall not alter the construction methods without permission ； Those who have not attended the briefing, do not understand its contents, or feel that the briefing was unclear should report this promptly; forced construction is not permitted. 4.2.12 Personnel entering the construction site must wear safety helmets properly, and it is strictly prohibited to enter the site while under the influence of alcohol. 4.2.13 When construction is being carried out directly above the furnace, no construction shall be performed in areas where heavy objects might fall, nor shall any protective devices be installed there. 4.2.14 During construction, dedicated supervisors must be assigned to monitor the lifted loads, cranes, and the surrounding environment, and report any abnormalities to the command personnel promptly. 4.2.15 The construction site should be kept clean; garbage and waste materials must be removed promptly, ensuring that the site is tidy once work is completed and all materials are used up, while adhering to civilized construction practices. 4.2.16 Unauthorized personnel shall not stay or pass through the lifting work area; it is strictly prohibited for anyone to pass through or stay under the crane boom and the lifted load. 4.2.17 Before lifting, the lifting equipment and its safety devices should be inspected. When the load is lifted about 10 cm off the ground, the lifting process should be paused for a thorough inspection; only after confirming that everything is in order can lifting proceed properly. 4.2.18 Operators of various construction machinery must receive professional technical training, pass safety regulations and practical operation tests, and obtain an operation certificate before they can operate the machinery independently. 4.2.19 The wire rope shall not be in direct contact with the edges and corners of objects; semi-circular pipes shall be placed at such edges and corners. 4.2.20 All tools used must be thoroughly inspected in advance to ensure they are in good condition; users must be familiar with their operating capabilities and pay attention to changes in dynamic forces during use, so as to ensure their proper and effective use. 4.2.21 All mechanical tools used, especially pulleys and winches, must be inspected in advance and used appropriately. 4.2.22 Platforms, walkways, ramps, etc. for work at heights shall be equipped with protective railings 1.05 m high and toe boards 18 cm high, or with protective vertical nets. 4.2.23 Safety belts should be fastened to secure locations; fall arrest devices may be considered for work at greater distances. 4.2.24 Openings around areas where work at heights is performed shall be covered with covers, safety nets, or fenced off. 4.2.25 All personnel involved in work at heights must undergo a medical examination. Those diagnosed by a doctor as having conditions that make them unsuitable for working at heights shall not engage in such work. 4.2.26 Workers performing work at heights should wear loose-fitting clothing; their sleeves and trouser legs must be tied up, and they should wear shoes with soft soles. 4.2.27 Objects exceeding the allowable load shall not be piled up at working heights, on various platforms, walkways, and scaffolds; construction materials should be lifted as they are needed. 4.2.28 Workers working at heights should carry tool bags, and larger tools should be secured with lanyards; throwing items is strictly prohibited when passing them around. 4.2.29 When working at heights, one must not sit on the edges of platforms or holes, nor ride on railings; one must not lie down on walkways or safety nets to rest. One must not work outside the railings or use them as a support for lifting objects. 4.2.30 A leakage protector must be installed when using power tools. 4.2.31 It is strictly prohibited to stand on the lifted object to lower chains or perform other tasks. 4.2.32 In electrostatic precipitators, lighting is powered by a safe low-voltage supply of less than 36V. 4.2.33 When performing maintenance inside electrostatic precipitators, it is necessary to strictly follow the maintenance procedures and protocols for entering and leaving such containers, in order to ensure the smooth progress of the maintenance work. 4.2.34 Major issues identified during inspections should be reported to higher-level management in a timely manner so that appropriate action can be taken. 4.2.35 It is strictly prohibited to throw tools and materials up or down; tools to be used daily must be placed in tool belts. 4.2.36 Smoking is strictly prohibited at the maintenance site, and those found violating this rule will be dealt with severely. 4.2.37 All staff must be conscientious and responsible during maintenance work, and must avoid working while under emotional influence or after drinking alcohol. 4.2.38 When using a sledgehammer, it is strictly prohibited to operate it with one hand or while wearing gloves. Before use, check whether the hammer head is securely fastened to prevent it from flying off and causing injury. 4.3 Measures for civilized construction of electrostatic precipitators in boilers
4.3.1 Work shall be carried out strictly in accordance with the “Technical Standards for Boiler Maintenance” and “Boiler Maintenance Operations”. 4.3.2 All on-site maintenance work is carried out in accordance with the ISO9002 quality assurance system standards. 4.3.3 All work must adhere to the principle of “four no-starts and five no-completions”. 4.3.4 Tools and parts at the site and in the tool cabinets should be arranged in an orderly manner. Parts removed from the electrostatic precipitator must be wrapped in plastic sheet and clearly marked for reinstallation. 4.3.5 The maintenance work area must be kept clean and tidy; it should be cleaned once daily at the start and end of work. 4.3.6 At the end of work, ensure that all tasks are completed, all materials are used up, the work area is clean, and the repair parts are tidy and clean. 4.3.7 Once running, leaking, dripping, or other such issues affect the working environment and site cleanliness, they must be cleaned up promptly. 4.3.8 All maintenance personnel must strictly abide by work discipline; fighting, playing, or any other activities that could cause negative consequences are strictly prohibited at the work site. 4.3.9 Strictly implement the entry and exit system for electrostatic precipitators. 4.3.10 After the maintenance tasks for the day are completed, the manhole cover must be sealed, and the lighting power supply used for the maintenance must be turned off. 4.3.11 The temporary power supplies and water pipes used for maintenance must be arranged horizontally and vertically to ensure cleanliness and aesthetics. 5 Organization and Division of Labor: 5.1 Organizational Measures: 5.1.1 During the maintenance of the boiler electrostatic precipitator, all workers must follow the unified instructions of the team leader ； 5.1.2 Members of each sub-team shall have clear roles assigned to them according to their responsibilities, and must not leave the maintenance site without permission ； 5.1.3 Convene a site meeting with all members prior to commencement and conduct safety and technical briefings ； 5.1.4 All staff present must maintain a good mental state ； 5.1.5 Work may only be carried out after all organizational, safety, and technical measures are in place. 5.2 Organization of labor personnel: Throughout the entire process of maintaining electrostatic precipitators, all workers must pay sufficient attention and remain focused, avoiding any mistakes. To this end, careful organization and a reasonable division of labor are essential during this process. During the maintenance of electrostatic precipitators, the team leader is fully responsible for the quality, safety, and orderly conduct of work at the site throughout the entire maintenance process.