Electrolyzer Preparation – Quick Review Notes

ABS Plate Setting

  • Use AKC torque-limited screwdriver (set to 3\,\text{N·m}); prevents cracking.
  • Temporary fix 1 m ABS plates ➔ level adjustment:
    • Measure 5 points/side; left-right deviation < 2.0 mm2.0\,\text{mm}
    • North-side deviation < 1.0 mm1.0\,\text{mm} (use piano wire)
    • Plate spacing = 2670±1.5 mm2670 \pm 1.5\,\text{mm}
  • Eliminate steps at joints (straight edge + emery paper).
  • Fill screw holes & gaps ≥1 mm1\,\text{mm} with 1:1 epoxy; tape edges, cure, smooth; silicone sealant acceptable substitute.
  • Final step: grease top surface for smooth cell-frame travel.

Insulation & Terminal Cell Frames

  • PP insulation plates t=10 mmt=10\,\text{mm}
    • Single press: 2 plates • Double press: 4 plates
  • Center plates evenly; handle gently.
  • Hoist terminal frames individually (weights: anode 558 kg558\,\text{kg}, cathode 581 kg581\,\text{kg}); keep area clear.
  • Align guide notch to ABS plates using lever jig; secure 4 points (loose-head: connecting bars; fast-head: turnbuckles).

Bipolar & PDT Frames

  • Hoist up to 12 bipolar frames at once (each 189 kg189\,\text{kg}); avoid shaking/hits.
  • Insert PVC spacers between frames (2 spacers for each terminal frame).
  • Install PDT frame at 25th position from anode (A001-B024-Z001 order).

Tank & Piping Cleaning

  • After construction: flush with water; bypass electrolyzers.
  • Fit #40 mesh screen on pump suction; inspect regularly.
  • Post-circulation: clean tank interiors; monitor pump cavitation.

Sub Header (S/H) Installation & Adjustment

  • Position per engineering docs; inlet S/H gradient = 1/2001/200.
  • Support S/H without obstructing nuts.
  • Hose routing: anode inlet ➔ anode outlet; cathode inlet ➔ cathode outlet; plug unused inlets.
  • Inlet hose: long leg toward cell frame; perform direction check at both ends & center of each half.
  • Adjust outlet nozzles so hose sleeve contacts gasket flat.

LI Valve Unit

  • Install before leak test.
  • Hose: PVC, 12×10 mm12\times10\,\text{mm} (PDT); height >3.1 m3.1\,\text{m}; folded end must reach floor drain.
  • Valves: anode = PVC (brown); cathode = PP (white).
  • Expect brine/caustic splash—wear protection.

Cathode Wire Inspection & Repair

  • PPE: thin rubber gloves (0.08 mm0.08\,\text{mm}), remove bulky gear.
  • Gently stroke cathode surface; feel welded areas & anode edges.
  • Inspection paths: (1) horizontal, (2) vertical, (3) edge.
  • Protruding wire: lift with tweezers, cut with nippers, re-check; avoid mattress compression.

Key AKC Supplies (excerpt)

  • Ion-exchange membrane, PP insulation plates, ABS plates, cell frames (terminal, bipolar, PDT), PVC/PP hoses, PVC spacers.
  • Auxiliary electrodes, nickel plates, titanium caps, lever jig, #200 mesh for hydraulic flushing, epoxy adhesive, locking pins.