Professional Documents
Culture Documents
Enviro Division
Installation &
Commissioning Manual
ELECTROSTATIC PRECIPITATOR
Thermax Group
The Rs. 2210 crore Thermax’s vision is to be a globally respected high performance company offering sustainable
solutions in energy and environment.
The Thermax Group provides business to business solutions in the areas of heating, cooling, captive power, water
treatment, air pollution control, waste management & resource recovery, and chemicals to a wide range of industry
in Indian and international markets.
In the energy business, Thermax executes projects in the areas of process heat, captive power and waste heat
recovery. It also offers a range of heating equipment, energy efficient chillers and customised products such as waste
heat and exhaust gas boilers. Thermax’s integrated expertise in energy has made GE to choose it as the ‘vendor on
first call’ for its global Combined Heating Power and Cooling (CHPC) projects.
Thermax provides energy solutions to utilise waste heat to burn waste gases and biomass. These include a variety of
customised turnkey solutions to generate heat, steam and power. It undertakes the entire range of activities from
concept to commissioning.
Clientele includes Cement, Steel, Non-Ferrous Metallurgical, Refineries, Petrochemicals, Fertilisers, Paper & Pulp,
Distilleries, Independent Power Plants, Chemicals and a wide range of other industries.
Thermax offers industry its expertise over a hundred fuels including oil, gas and a wide variety of solid fuels including
biomass. Thermax Babcock & Wilcox (TBW) has emerged as a leading and reliable project management company
with installations the world over; in the US, Saudi Arabia, Thailand, Egypt, Philippines and several other countries.
Leveraging its leadership position in electricity saving, vapor absorption technology, it offers process industries and
commercial establishments like hotels, shopping malls and offices vapour absorption chillers, a boon in power-
starved areas. These eco-friendly, energy efficient equipment have found prestigious customers such as BBC,
Mercedes Benz, Audi, Bosch, Panasonic, Henry Ford Museum.
In the environment area Thermax offers waste management expertise for solid, liquid and air pollution. Thermax
provides solutions from pre-treatment to waste water treatment and chemical conditioning of water for boiler and
cooling water systems. Water recycling is a thrust area for Thermax. Hi-grade resins from Thermax have found niche
customers in US and Japanese markets.
Thermax is a key player in the field of gaseous and particulate emission control, with special focus on the emerging
gaseous scrubbing business in India. Our state-of-the-art technology enables us to offer turnkey project as well as
air pollution control products. And, the greatest utility of these solutions stems from the fact that they allow resource
recovery in process industries.
Thermax has an extensive international marketing network. Headquartered in Pune (Western India), Thermax’s
eleven international offices are located in South East Asia, Middle East, Africa, Russia, UK and the US. Thermax (Rus)
Ltd., Thermax (Europe) Ltd., Thermax Inc., USA and ME Engineering, UK. Around 20 percent of the group's turnover
come from exports to the US and European markets, Japan, East Africa, the Middle East, South East Asian and CIS
countries.
The Thermax group’s manufacturing facilities, spread over 14 plants, measuring a covered area of over 65000 sq.
Mts., are ISO 9000 and ISO 14001 accredited. Thermax manufactures to international standards like ASME, BS,
DIN and GOST. The facilities have been inspected by Lloyds, Bureau Veritas, SGS and TUV.
Thermax’s business is inspired by the conviction that ‘Improving your business is our business’.
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Enviro Division
DIVISIONAL PROFILE
Enviro Division
Strongly believing that pollutants are inevitable but pollution is not, the Enviro Division was set up in 1980. Today,
Thermax is one of the only organizations in India having an active presence in the entire spectrum of Air Pollution
Control & Air Purification business, and is an acknowledged leader in most industrial segments. On offer is a full
range of flange-to-flange products, customized systems and value-added services. Solutions from Thermax Enviro
are present across industries and application segments, be it cement, steel, non ferrous metallurgical, power plants
and process boilers, fertilizers, tyres & tubes, paper, chemicals & petrochemicals, textiles or food & beverages - this is
just to mention a few.
Total Solutions in Air Pollution Control
+Electrostatic Precipitators - Dry & Wet
+High Efficiency Cyclones, Multiclones and Spray Cyclones
+Baghouses - Reverse Air, Pulse Jet & Insertables
+Particulate Scrubbers - Venturi, Cyclonic, Impingement Plate
+Gaseous Scrubbers - Packed Bed, Spray/Tray Towers
+Flue Gas Desulphurization (FGD) systems
+Dedusting & Fume Extraction Systems
+Coal Preparation Plants & Coal Injection Systems
+Pushing Emission Control Systems for Coke Ovens
+Retrofitting & Rebuilding
+Spares & Service
Air Purification Systems with Chemical Air Filters
The Purafil Range (for removal of corrosive, toxic and odorous gases):
+Equipment
+Media
+Instruments
The division also undertakes turnkey projects to offer complete technology in air pollution control. The division has
the expertise to handle projects from 'concept to commissioning' and tailor systems to suit the exact process
requirements. Enviro Division of Thermax is adequately equipped to offer field services for erection &
commissioning, annual maintenance contracts, repairs, retrofit & rebuild, supply of spares, trouble shooting and
customer training for its entire range of products.
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ELECTROSTATIC PRECIPITATOR
Electrostatic Precipitator
Contents
Installation & Commissioning Manual ELECTROSTATIC PRECIPITATOR
Contents
1. INTRODUCTION 01
14. PRECAUTIONS FOR SMOOTH & TROUBLE FREE FUNCTIONING OF ESP 174
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ELECTROSTATIC PRECIPITATOR
Chapter 1
Introduction
Installation & Commissioning Manual ELECTROSTATIC PRECIPITATOR
Introduction
This guideline manual covers the main features of ESP installation and commissioning of THERMAX make
Electrostatic Precipitators. The instructions given in this guideline manualare not intended to explain all installation
and commissioning work in detail. This guideline manual has been prepared with a view to the following:
Though, it has been endeavored to make this manual comprehensive and complete, to offer the best guideline for
installation, there may still be questions regarding the finer aspects of the installation and alignment of ESP. There is
a team of qualified and experienced erection engineers / supervisors who can assist in solving special problems
related with ESP installation and commissioning.
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ELECTROSTATIC PRECIPITATOR
Chapter 2
Guidelines on Health
& Safety Measures
Installation & Commissioning Manual ELECTROSTATIC PRECIPITATOR
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ELECTROSTATIC PRECIPITATOR Installation & Commissioning Manual
14. While shifting the material from store yard / assembly point to erection site the necessary safety precautions to
be taken to avoid the fall of material, that could result in serious accident.
15. The main distribution board at all places should be with ELCB (Electric Leakage Circuit Breaker), of sufficient
capacity / rating (30mA). Also TPN (Three Phase Neutral) facility should be provided, near ESP erection &
assembly site.
16. Whenever required, use the proper extension board. Always avoid the unsafe practices of cable joints like
cable joints by twisting the cable strands and using plastic on it, etc. Always use proper sockets and plugs for
individual equipment.
17. No personnel should put their fingers inside the rotating machines, while machine is in operation.
18. Before taking trials / operating the rotating machinery, the coupling guards must be fixed at their positions. If
any foreign member / items are fixed on such rotating machinery during installation & alignment, it should be
removed before taking any trials of rotating machinery.
19. Fire extinguishers should be available (minimum 2 nos.) at site for electrical and other type of fires.
20. Safety postures should be displayed at site. Also tool-box talk should be imparted regularly at site for all
workmen. The proceedings of tool box talk should be recorded regularly.
REFER THE SAFETY RISK ASSESSMENT SHEETS ENCLOSED SEPARATELY WITH THIS MANUAL.
Thermax’s Health, Safety and Environmental policy copy is attached with this for reference.
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Installation & Commissioning Manual ELECTROSTATIC PRECIPITATOR
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ELECTROSTATIC PRECIPITATOR
Chapter 3
Principle of ESP
Operation
Installation & Commissioning Manual ELECTROSTATIC PRECIPITATOR
The Precipitator uses electrical forces as a means of achieving this function. In the precipitator, the gases to be
cleaned are evenly distributed over the whole crosssection of the ESP by means of distribution screen, vanes and
baffles, which are placed inside the inlet nozzle and channeled through gas passages formed by parallel rows of
collecting plates.
Discharge electrodes (Regitrodes) are suspended in a plane midway, between each pair of collecting plates.
A negative high tension DC Voltage, produced by high voltage transformer rectifier sets, is applied to the Regitrodes
while the collecting plates / panels are connected to the earth. The negative high tension DC voltage applied to
regitrodes induces ionization of the gas molecules adjacent to high voltage discharge electrodes called Corona
Discharge. The positive ions, thus generated, migrate towards the negative charged discharge electrodes and the
negative electrons towards the earthed collecting plates. On their way to the opposite polarity electrodes, these
electrons and ions attach themselves to the dust particles and charge the dust particles. The electrical field between
the electrodes causes the charged dust particles to move towards the collecting plates, where they get deposited and
form a layer.
Depending on the nature of particulate matter, the dust layer is periodically rapped off the collecting plates to fall
down into the bottom hopper.
Some dust particles may always stick to the gas distribution devices, thus influencing the uniform distribution of gas
across the ESP cross section. To avoid such influence and to keep the gas distribution screens clean, they are also to
be periodically rapped. The dust, which collects in the hopper, is off-loaded to a dust conveying system.
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ELECTROSTATIC PRECIPITATOR
Chapter 4
Facilities
Installation & Commissioning Manual ELECTROSTATIC PRECIPITATOR
The above facilities are considered adequate for a single supervisor. If necessary, such facilities should be made
available for additional engineers / supervisors.
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ELECTROSTATIC PRECIPITATOR
Chapter 5
Guidelines on Storage
Facilities
Installation & Commissioning Manual ELECTROSTATIC PRECIPITATOR
Storage Instruction
In mutual interest for a trouble free erection, handling of the material should be as below:
1. Large steel structural parts, delivered unpacked, for example casing, hopper, inlet nozzle parts etc. have to be
properly stacked on a flat surface (not lying on the floor) with adequate packing to avoid sagging.
2. The special long and straight parts of ESP internal like collecting plates/ discharge electrodes, their
suspension arrangement, girders etc., are also to be kept on a flat surface with sufficient care and adequate
packing. It is essential not to have too many parts above each other, because the parts below can get
damaged.
3. All accessories delivered in crates, especially electrical parts, such as TR sets, geared motors, controllers,
electrical panels, heaters, thermostats, insulators etc., must be stored in a covered dry room.
4. Material delivered in boxes must be stored in a dry place, as it may contain the electrical & instrument
components.
5. During handling of the parts, observe the various markings and then lift material.
6. The high-voltage rectifiers are delivered in boxes. These particular boxes have to be handled very carefully
and they can only be lifted at the marked places.
7. Do not store any material in sloping position (oil content).
8. If THERMAX erection engineer is already at site at the time of arrival of material, his suggestions shall be taken
before unloading the parts, since he will know which parts are required first and accordingly he can advice for
unloading of the material.
9. If the material arrive before THERMAX erection engineer, suitable people are to be deputed to supervise the
unloading. Under no circumstances let the transporter unload the material without supervision. From
experience, THERMAX know that rough handling slows down the erection work by necessitating much
adjustment and repair work at later stages.
10. For unloading, handling and storage of the ESP internals, follow the special directions as given below.
a. Before unloading the electrodes the storage space has to be leveled with squared timber.
b. The crates of collecting plates, as eventually also the single plates, have to be stored with their wide side
upright to avoid sagging of the collecting plate.
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ELECTROSTATIC PRECIPITATOR Installation & Commissioning Manual
c. While unloading with crane, provide a lifting device. Lift the crates always with four slings of rope (protect
the four points of attach) and leave them in their original position without turning.
11. IS 2062 / IS 1079 steel ESP material, with factory primer painting, should not be exposed to rain or excessive
dampness for more than one month. Otherwise rust spots may appear. The material may be finish coated to
prevent rust during prolonged periods of outdoor storage in damp climates. All openings should be covered
with suitable material to protect interior surfaces from outside.
ATTENTION: Non observance of the above instructions will absolve THERMAX from every liability
concerning erection problems.
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ELECTROSTATIC PRECIPITATOR
Chapter 6
Guidelines on Receiving &
Stacking of Material
Installation & Commissioning Manual ELECTROSTATIC PRECIPITATOR
Stacking of Material
a. Support Structure: The support structure is fabricated from MS structural members like channel, angle,
beam. The support structure can be stacked in open and over sleepers, to keep it above earth to prevent the
rusting. All supporting structure material should be stacked at one place. This would help in easy material
identification during its shifting and installation.
b. ESP Casing, Hopper, Nozzle: The ESP casing, nozzle and hopper are fabricated mainly from MS plates with
strengthening members like angle, channel, beam. These materials also can be stacked in open but over
sleepers, to prevent its rusting. These materials should be stacked properly and should not dumped on each
other. This is to avoid the damages to these materials, if they are stored for longer period. Keep the panels
stacked one over the other but not more than 5 panels.
c. Stair - case, Platforms, Monorail: These parts are also fabricated from structural members like channel,
angle, beams. These materials can also be kept together in open. However, due to large number of small
structural loose members, it is better to stack them together systematically. All loose small members should be
properly stacked.
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ELECTROSTATIC PRECIPITATOR Installation & Commissioning Manual
If gratings are supplied loose, all such grating should be stacked one over the other, size wise. Handrails are
prone to pilferage and hence should be kept separately and safely.
d. Collecting Plates and its allied parts: Collecting plates are very delicate items, which should be handled
very carefully at site. On receipt at site, collecting plates should be unloaded by spreader beam. DO NOT
UNLOAD COLLECTING PLATES WITHOUT SPREADER BEAM. Stack the collecting plate crates over the
wooden sleeper as shown in the sketch (Refer schematic sketch no. 001) Always ensure that the collecting
plate profile is in vertical direction, while stacking the collecting plate crates. Keep only 3 crates one over the
other. Cover the collecting electrode crates with tarpaulin, if it is to be kept for more than one month or if rains
expected. Other components of the collecting plate assembly like top tadpole, bottom tadpoles should be
stacked in covered area or should be covered. No rusting should be allowed on these parts while they are
stored.
e. Regitrodes and its allied parts: The regitrode pipes with spikes are supplied in the steel crates. These crates
should be stacked over wooden sleeper in their original packing, absolutely away from earth. All Rigitrode
tubes should be kept under covered storage over wooden sleepers and care must be taken to avoid kinks.
NEVER ATTEMPT TO LIFT A PACKAGE OF RIGITRODES USING FORKLIFT!
f. TR set, TRCC and other Panels: These should be stored under covered and dry place. Also these items
should be protected from rains and dust. On receipt of the TR sets, TRCC and other panels at site, check the
boxes for any damages. After inspection close the boxes again and nail it.
g. Insulation Material: Insulation material mainly consists of mineral / resin bonded rock wool, aluminum
sheet and other hardware. Ensure that mineral wool and aluminum sheets are kept under covered shed and
protected from rains and any other water ingress.
h. Electrical Items: All electrical items and instruments should be checked for any damages and should be kept
in stores protected from any mechanical damages, pilferage. All support insulators should be checked for
damages and cracks.
How to check a support insulator for cracks? The support insulators can be checked by a simple sound test.
For this, take the insulator out of wooden packing and rest it on a wooden plank. Support it on one of its edges
vertically and give a light blow of wooden mallet. If you get a ringing sound, the insulator is okay. If you get a
blunt sound, there can be some crack. This will have to be checked properly by moving your hand all round
the insulator from inside and outside and feel for any cracks.
i. Dust Conveying System: Dust conveyors, pneumatic system should be unloaded and kept in yard over
wooden sleepers. All materials of dust conveying system should be covered with tarpaulin. In case of RAV
(Rotary Air Lock Valve), it should be stored in the covered space, to avoid the damages to the geared motor
during its storage period.
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Installation & Commissioning Manual ELECTROSTATIC PRECIPITATOR
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ELECTROSTATIC PRECIPITATOR
Chapter 7
Standard ESP Activity
Chart
Installation & Commissioning Manual ELECTROSTATIC PRECIPITATOR
15.1 Cable Termination 15. Alignment of regitrodes w.r.t. 15.2 Erection & Alignment of Inlet
collecting plates GD Rapping System
16.1 Cable Dressing 16. Air leak test 16.2 Thermal Insulation
Application
(After Air Leak Test)
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ELECTROSTATIC PRECIPITATOR Installation & Commissioning Manual
For the above mentioned ESP erection activities, the requirement of Thermax's supervising engineer's site visit, to
check and guide for the ESP erection activities are indicated as below
Approx. Day of TL
Activity No.
Engineer
1 2
2 2
3 3
4
5 5
6
7
8 3
9
10
11 2
12
13 2
14
15 4
16 3
17
The above numbers of days are to be maintained, to have effective & efficient usage of Thermax engineers limited
supervision days.
The above-tabulated ESP erection activities are briefed below in two separate sections as PreErection Activities and
Erection activities and these activities are briefed below.
The standard Field Quality Plan (FQP) for ESP erection activity is enclosed with this for ready reference.
13
THERMAX LIMITED, ENVIRO DIVISION, PIMPRI, PUNE 411 018THERMAX
FIELD QUALITY PLAN FOR ESP Document No.: TL/ENV/FQP-ESP/38 Rev. 0 dtd. 15.03.06
Method
Sr. No Description Characteristics to be Method of check Extent of Acceptance standard Erection Thermax Customer
of
checked check Agency
Record
14
Penthouse dimensions)
Primer touch Visual 100% As per specification P W W
Method
Sr. No Description Characteristics to be Method of check Extent of Acceptance standard Erection Thermax Customer
of
checked Agency
15
check Record
5. Collecting Plate Identification Visual 100% As per Drawing P R W
System Condition Visual 100% Good Condition P W W
Straightness at plate Use 100% Straight within +/- IR P W W
end straightness jig 3mm
Fit up Visual 100% As per Drawing P W W
Alignment Verticality Random Within +/- 4mmg IR P W W
Spacing Random As per Drawing IR P W W
6 Regitrode Identification Visual 100% As per Drawing P R W
System Condition & Visual 100% Good Condition & P W W
Healthiness Straight Pins
Straightness Straight in 100% Straight within +/- P W W
hanging 5mm
condition
ELECTROSTATIC PRECIPITATOR
Fit up Visual
Alignment Measurement 100% As per Drawing IR P W W
Functional check Visual 100% Direction of rotation & PCR P W W
Current drawn
13. Leak Testing Identification of As described 100% Air Leak Test Protocol P W W
of ESP Welding Leakages below
14. Thermal Identification Visual 100% As per Drawing IR P W W
Insulation
15. Cable laying Identification Visual 100% As per cable schedule P R W
/ Termination Cable Laying Visual 100% As per drawing P R W
and Earthing Cable Routing Visual 100% As per drawing P R W
Cable Termination Terminal points 100% As per cable schedule P R W
16
TR -ve bushing primary & secondary
to earth current
Method
Sr. No Description Characteristics to be Method of check Extent of Acceptance standard Erection Thermax Customer
of
checked check Agency
17
Record
Open Circuit By keeping TR 100% To rated value of PCR P P W
Test IR Test -ve bushing open primary &secondary
voltage
As per electrical wiring
diagram
20. Air Load Test As per Thermax Energising TR 100% As per Pre- PCR P P W
Standard Format panels & TR sets commissioning Report
with ESP fields.
Installation & Commissioning Manual
Note on Leak Test Procedure:
A) After completion of all mechanical erection activities and before starting application of insulation, leak test is to be carried out. This is
to ensure that there are no welding leakages in the ESP.
B) After ESP is boxed up, i.e. after fixing all access doors, rapper seals, insulator heaters, thermostats, hopper level probes, blank ESP inlet
and outlet either by closing the dampers (if they are available) or by fixing a blanking plate with its seal welding. Connect the Purge Air
blower directly to the penthouse. Blank all other openings e.g. hopper outlets etc. in the ESP by dummy plates.
C) Then start the Purge air blower and pressurise the ESP upto 100mmWC.
D) Pour the soap water on all site weld joints (with the help of water tube) and observe for any bubble foam. In case of weld joint leakage
bubble will be formed. Mark all such points and weld them. Repeat till no leakages are observed. During this testing keep sufficient stock
of soap water (approx. 30 liters) over penthouse.
Installation & Commissioning Manual
Legends:
P -Perform; W -Witness; R- Review; IR -Inspection Report; PCR- Thermax's PreCommissioning Reports
ELECTROSTATIC PRECIPITATOR
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ELECTROSTATIC PRECIPITATOR
Chapter 8
Guidelines on ESP
Pre-Erection Activities
Installation & Commissioning Manual ELECTROSTATIC PRECIPITATOR
Measure the axial & diagonal measurement and record it as per the format given in schematic sketch no. 005.
If the foundations bolt pocket fauls to any of the centerline, the pocket needs to be chipped in line with the centerline
measurements, to have the foundation bolt at correct location, as per centerline requirement.
d. After checking & ensuring the centerline of footings, foundation bolt grouting is to be done, as briefed below
+Insert the foundation bolt in pockets.
+Place the template on footing, with leveled packing of approx. 50mm and bolt the foundation bolts with
template.
+To check the sufficient clearance between foundation bolt w.r.t. respective pocket side wall, rotate the
foundation bolt about. If foundation bolt is rotates freely, it indicates that there is sufficient clearance between
pocket side wall and foundation bolt. If foundation bolt touches the pocket wall, the respective side of pocket
need to be chipped out, to have sufficient clearance between foundation bolt and pocket wall, as briefed
above.
e. After ensuring the freeness of foundation bolt in all pockets, the foundation bolts alignment to be done. For
this purpose, following steps to be followed
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ELECTROSTATIC PRECIPITATOR Installation & Commissioning Manual
i. Check & ensure that the top level of template is same as that of support structure base plate top level,
indicated in General Arrangement drawing.
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Installation & Commissioning Manual ELECTROSTATIC PRECIPITATOR
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ELECTROSTATIC PRECIPITATOR Installation & Commissioning Manual
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Installation & Commissioning Manual ELECTROSTATIC PRECIPITATOR
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ELECTROSTATIC PRECIPITATOR Installation & Commissioning Manual
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Installation & Commissioning Manual ELECTROSTATIC PRECIPITATOR
After completing the assembly of nozzle, the inlet GD screen assembly & its locking with nozzle should be done.
1. All GD screen plates are supplied in CKD condition, to facilitate easy transportation.
2. Place the GD screen sheets as per inlet GD screen drawing (i.e. % opening wise).
3. Ensure the axial and diagonal dimensions as per drawing and within acceptable tolerances. (For axial
dimensions the variations should be within +/- 5mm and diagonal dimensions should be +/- 8mm). Tack
weld the screens while bringing it within acceptable tolerances.
4. While assembling the GD screens, if any GD screen holes overlaps to each other, the overlapping portion can
be gas cut and such gas cut portion to be cleaned by grinding only.
5. After ensuring the dimensional measurements, weld the screen sheets to each other as shown in referred inlet
GD screen drawing. While welding the GD screen welding, ensure that sufficient care is taken to avoid the
screen's distortion / warpage.
6. Once the GD screen welding completed, re-check and ensure the screen dimensions again.
7. Weld the GD screen hanging arrangement on nozzle's top plate, as shown in referred drawing.
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ELECTROSTATIC PRECIPITATOR Installation & Commissioning Manual
8. Hook the screen top to its hanging arrangement as shown in referred drawing.
9. Lock the screen to nozzle side plate, as shown in drawing. This locking shall be done from screen's top end &
followed to its bottom end.
10. In normal condition, the GD screens are kept in vertical hanging position. However, while doing its assembly,
the screens are to be kept in horizontal position. In such position, the assembled screen tends to develop the
bend / bow, if it is not supported properly. Hence while hooking / locking the screen with nozzle, sufficient
temporary supports shall be provided at needed locations.
11. Such temporary supports are to be provided for all GD screen assemblies.
Following is the brief guideline for assembly of casing panels with adjacent casing column.
a. Please refer and study the casing assembly drawing, sent separately, prior to start of ground assembly of
casing columns and panels.
b. While assembling the casing columns and panel, refer the reference drawing, along with schematic sketch
nos. 007 to 029.
c. Place the two adjacent casing columns on assembly platform. Ensure that the column's face, on which the
casing panels are to be placed, is facing upwards.
d. Check & ensure the center distances of columns are maintained as per drawing, along with its diagonals.
e. Check the straightness of casing column base plate and its position w.r.t. adjacent column. Here check &
ensure that the base plates of these columns are in same level and the hole centers provided on column base
plates are with correct diagonal.
f. After ensuring the correct center distances as per reference drawing, lock the column assembly by welding
temporary members like angle or channel.
g. Place the casing panels on these aligned columns and do the proper fitment with columns.
h. After completion of casing panel fitment to columns, re-check the alignment (i.e. center distances &
diagonals) and make sure that they are not disturbed. After, re-ensuring the alignment, stitch welding of
casing panel with casing columns and casing panels to panels can be done on the upper side.
i. Once the stitch welding is completed, turn around the casing panel, so that the seal welding of casing panel
with casing column and casing panel to panel can be done on opposite side of assembly.
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Installation & Commissioning Manual ELECTROSTATIC PRECIPITATOR
While rotating the assembled casing panels, due safety precautions should be taken to avoid any kind of
accidents (to man / or to assembled components). While doing the seal welding, sufficient care should be
taken to avoid the distortion of assembled component due to welding. The practices like staggered welding /
welding in stages can be followed. If required, provide the temporary locking arrangement to avoid the
welding distortion.
j. Once the seal welding is completed, the weld joints are to be checked for its weld defects and to be corrected,
if any defects were found. Then the kerosene test should be conducted to ensure that the welding is free from
defects.
Similar procedure shall be followed for assembly of other pair of casing columns and casing panels.
After completing the assembly, the assembly should be stacked properly on a leveled surface, with wooden packing.
This is required to avoid the bending of the assembled components while they are stacked.
G. Hoppers
a. All hopper parts (except bottom portion) are supplied in CKD condition, for easy transportation of hopper
parts.
b. For reference, refer hopper assembly drawing (which is sent separately), along with the typical sketch nos.
from 008 to 029, attached with this.
c. Based on the erection clearance available, a hopper can be assembled in one or two pieces (heightwise). This
is to be decided mutually between customer and contractor.
d. While doing the ground assembly, sufficient ground clearance (approx. 800mm) shall be provided between
leveled surface and hoppers bottom edge, for access (for man & cables) & also for proper ventilation inside
hopper, during assembly.
e. Place and assemble the hopper panels as per referred drawing and attached sketches.
f. While assembling the hopper, ensure that all inside pipe supports are provided at correct locations, shown in
referred drawing.
g. Prior to start the seal welding, check and ensure that hopper opening dimensions are correct, as per drawing
and are within acceptable tolerances. (For axial dimensions the variations should be within +/- 5mm and
diagonal dimensions should be +/- 8mm).
h. After seal welding, all seal weld joints are to be checked for any visual welding defects (e.g. blow holes /left
out welding spots) and to be rectified.
i. After weld defect rectification, all weld joints are to be tested for its leakages by kerosene test method.
The above procedure shall be followed for assembly of other hoppers.
All the assembled hopper parts are to be stacked properly on a leveled surface, with wooden packing. This is
required to avoid the defects to assembled components while they are stacked.
H. Penthouse Panels with columns
To avoid the position fit-up and welding of penthouse panel with its columns, the penthouse panels with its adjacent
columns can be assembled on ground and can be kept ready for erection. This shall be decided based on the
capacity and safe approach of lifting equipment available at site.
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ELECTROSTATIC PRECIPITATOR Installation & Commissioning Manual
Following is the brief guideline for assembly of penthouse panels with its adjacent columns.
a. Refer the penthouse assembly drawing and attached schematic sketch nos. from 064 to 066, prior to start of
its ground assembly.
b. Place two adjacent penthouse columns on assembly platform. While doing this, ensure that the column's face
where the penthouse side panels will be fitted & welded, is kept facing upwards.
c. Check the straightness of penthouse column and its position w.r.t. adjacent column. Also ensure that the base
of both columns is in same level, with correct diagonal, as shown in sketch of casing side panel assembly
(Sketch no. 007).
d. Maintain the distances (center & axial) of penthouse column assembly as per drawing. Also ensure that the
diagonals are within limits (Axial distances should be within +/- 4mm and diagonals should be within 8mm).
Then lock the column assembly by welding the temporary angle / channels, to avoid the disturbance to its
aligned position.
e. Place the penthouse panel on these aligned columns and do the proper fitment with columns.
f. After panel fitment to columns, re-check the alignment (i.e. center distances & diagonals) and ensure that they
are not disturbed.
g. Once the alignment is confirmed, stitch welding of panel with column to be done.
h. After completing the stitch welding, turn around the assembly, so that the seal welding of panel with column
can be done on opposite side of assembly. While rotating the assembled panels, due safety precautions
should be taken to avoid any kind of accidents (to man / or to assembled components). While doing the seal
welding, sufficient care should be taken to avoid the distortion of assembled component due to welding. The
practices like staggered welding / welding in stages can be followed. If required, provide the temporary
locking arrangement to avoid the welding distortion.
i. Once the seal welding is completed, the weld joints are to be checked for its weld defects and to be corrected,
if any defects were found. Then the kerosene test should be conducted to ensure that the welding is free from
defects.
Similar procedure shall be followed for assembly of other pair of penthouse columns and penthouse side panels. All
the assembled columns and panels are to be stacked properly on a leveled surface, with wooden packing. This is
required to avoid the defects to assembled components while they are stacked.
I. Top HV Frame
The top HV frame is supplied in semi-assembled condition.
All these semi-assembled parts are to be assembled at site, on a leveled surface, as per drawing, that is sent
separately. While assembling the top HV frame, the dimensions indicated in reference sketch no. 030 should be
maintained.
Prior to assembly, check the parts of HV frame for its straightness, as there is possibility of damaging the parts during
transporting or unloading at site.
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9 10 11
12 13
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15
17
16
18 19
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Sketch No. 30
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Chapter 9
Guidelines on ESP
Mechanical
Erection Activities
Installation & Commissioning Manual ELECTROSTATIC PRECIPITATOR
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h. After completing the support structure alignment, protocol should be made and alignment readings should
be recorded as per the format given in sketch no. 031 & 032.
i. Only after completing the support structure alignment, welding of support structure bracing should be done.
j. While welding the bracings, the thought on the erection of collecting plate, regitrode, hopper should be
given.
The bracings, which may foul while doing the erection of above components, shall not be welded. It can be
kept on bolts. These bracings shall be welded after completing the erection of above ESP items.
HOLD POINT: TILL SUPPORT STRUCTURE ALIGNMENT IS COMPLETED WITHIN THE ACCEPTABLE
TOLERANCES, FURTHER INSTALLATION SHOULD NOT BE DONE.
Note: The support structure grouting should not be done till the bearing erection and alignment is completed and
accepted.
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Sketch No. 31
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Sketch No. 32
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Bearing No. A1 B1 A2 B2 A3 B3 A4 B4
Spirit Level
Inspection
Point Water Level w.r.t.
Fixed Bearing
Mark v if inspection point is as per above tolerance guidelines and mark X if it is not as per tolerance guidelines.
Note: To ensure the correct elevation of bearing top and spirit level of bearing top plate, the needed packings
should be given only at base of support structure column and not below any bearings.
vii. Once the checkpoints (as mentioned above) are ensured, the bearings can be locked with respective
columns, by welding a thick flat piece.
ix. Once the alignment is completed, the alignment readings are to be recorded as per the enclosed format
(Sketch 35).
x. After completion of bearing alignment, further erection can be started.
HOLD POINT: FURTHER ERECTION OF ESP ON ESP BEARINGS SHOULD NOT BE DONE, UNTIL
COMPLETION AND ACCEPTANCE OF BEARING ALIGNMENT.
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Sketch No. 33
Sketch No. 34
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Sketch No. 35
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xii. After completing casing alignment, protocol can be prepared and the readings are to be recorded as per the
format given in schematic sketch nos. 036 & 037.
xiii. After completing and accepting the casing alignment, welding of top / bottom girder with respective columns
should be done, as shown in reference drawing / sketch.
HOLD POINT: FURTHER ERECTION OF ESP COMPONENTS SHOULD NOT BE DONE, UNTILL
ACCEPTANCE OF CASING ALIGNMENT AND WELDING OF GIRDER WITH COLUMNS.
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Sketch No. 36
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Sketch No. 37
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E. Erection, Alignment and welding of Staircase & Platforms with Access Doors
i. After completing casing alignment and welding, the staircase and platform erection should be done, to have
proper access on ESP top.
ii. For reference purpose, the staircase & platform arrangement drawing along with the attached schematic
sketch nos. 038 to 042 should be referred.
iii. The staircase & platform erection shall be done in following three stages
a. Erection of staircase & platform upto casing access door level
b. Erection of casing access door level platform
c. Erection of staircase & platform above casing access door level platform
d. Erection of hopper access door level platform (if applicable)
Here the staircase & platform installed on & above the ESP bearings shall be kept free, by not welding the
staircase / platform member with support bracket. This is to ensure the expansion of ESP with its structure
(above bearing level). Refer the sketch no. 038 for reference.
iv. While fixing the stairs, ensure the correct angle of the stair's grating from safety point of view.
v. After completion of the casing access door platform, the openings for casing access doors can be made on
the casing panels. Fix the casing access doors on these opening. All these doors are to be seal welded from
inside and stitch welded from outside. Refer the attached sketch nos. from 109A to 109C for fixing the doors.
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Sketch No. 38
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51
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Sketch No. 43
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Sketch No. 44
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Sketch No. 45
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b. After correct assembly of jig, place the top tadpole on the jig towards top end.
c. Then slip the collecting plates inside the top tadpole and secure the fasteners of collecting plates and
top tadpole, loosely.
d. Place the bottom tadpole at bottom end of jig and slip it on bottom end of collecting plates. Secure the
fasteners of collecting plates and bottom tadpole, loosely.
e. For EEC type of collecting plates, the interlocking of collecting plate to plate is to be done by press fitting
of the collecting plate end profile into each other. For this purpose wooden mallet /mallets with fiber tips
can be used. Where as for GE type collecting plates there is no such plate to plate interlocking.
However, the plates are inter connected with the help provide space as M6 X 24 fasteners.
f. After ensuring the correct interlocking or fixing the fasteners, tighten the tad pole fasteners (top &
bottom) of collecting plates. While tightening the fasteners, the collecting plate assembly should be
checked and ensured for its measurement, especially diagonals. The diagonals of the assembly must
be within +/- 4mm where as axial measurements can be kept within +/-5mm.
g. Once the plates are assembled within the above acceptable tolerances, following welding (stitch) shall
be done. For this refer the sketch no. 047 & 048.
+Staggered welding of collecting plate with top tadpole at both top & bottom side.
+Staggered welding of collecting plate with bottom tadpole on both top & bottom side.
+Stitch welding of collecting plate to plate interlocks.
+Welding of bolt M20x40 at the end of bottom tadpole.
h. Once the first collecting plate is assembled and accepted, necessary guide / locking should be welded
on the jig, in such a way that these guide / locking would help in easy assembly of further collecting
plate assemblies.
The above steps should be followed for all further collecting plate assemblies. A record sheet should be maintained
giving the numbers to assembled collecting plate and it's dimensional measurements, as shown in sketch no. 047.
i. While stacking the assembled collecting plates, ensure that the surface, on which the assemblies are
being stacked, is plain and wooden sleepers & packings are used while stacking the plates.
j. The assembled plate should be shifted manually nearer to the erection spot. To remove the plate from
assembly jig, wooden battens / plain pipes should be used be used. For removing the plate from jig, lift
the plate assembly from one end (longer side) and insert the wooden battens / plain pipes below
collecting plate assembly. Such pipes shall be given at minimum 3-4 locations (spaced equally in its
entire length / longer side). This is needed to avoid the damages to the plate assembly while it is being
shifted.
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Erection Tools
Sketch No. 46
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k. Place the plate assembly on wooden sleepers (placed at 4-5 locations, spaced equally in its entire
length and are placed on leveled ground). If the surface on which the plates are being stacked, is not
plain leveled and sufficient wooden sleepers are not used, the plate assemblies can get damaged.
l. Ensure that only 9 plate assemblies should be stacked over each other. Due to weight of upper plate
assemblies, there are always chances of damaging the lower plate assemblies. Hence more plates
should not be stacked on each other. Also ensure that the sufficient wooden packings (placed at 4-5
locations, spaced equally in its entire length) are provided between two assembled collecting plates.
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Sketch No. 47
Sketch No. 48
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Erection Tools
Sketch No. 49
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Sketch No. 50
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h. Run the winch rope in such a way that the wire rope does not scratch to any part of ESP incl. its civil foundation.
i. Place a channel box (fabricated from ISMC 200), on respective field’s top girder as shown in attached sketch
no. 051.
j. Place the lifting frame near erection spot.
k. Once all above preliminary arrangements are made, take no load trial run / dry run of lifting arrangement,
first by running the system with lifting frame only.
l. After successful dry run trial, the plate assembly can be shifted from the stacked area. For shifting the plate
assembly from stacked area, similar procedure should be followed, as it was followed for shifting of the plate
assemblies from assembly jig to stacking area.
m. Insert the plate assembly in the lifting frame and lock it properly, to avoid its falling down / slipping during its
lifting. Refer the attached sketch no. 050. The plate assembly should not be tied permanently with lifting
frame, as it would result in un wanted problems while removing the frame, after plate assembly is fixed in its
position in the floating channel.
Note: COLLECTING PLATE INSTALLATION IS NOT ALLOWED WITHOUT USING LIFTING FRAME.
n. Once collecting plate assembly is inserted and locked in lifting frame, the frame should be lifted using winch
and can be taken to the position where it is to be placed i.e. inside floating channel. Refer sketch no. 051.
When lifting frame is in hanging position, there is a possibility of swinging or rotating the lifting frame. This
swinging or rotating of the frame would damage the plate assembly. To control this, two manila ropes shall be
tied at both bottom corners of the lifting frame and with help of these ropes the swinging or rotating of frame
should be controlled.
o. While positioning the plate assembly inside floating channel, little shaking to floating channel might be
required (may be not for first plate but during fixing the further plates)
p. After positioning the plate assembly inside floating channel, the plate assembly positioning should be
secured, by fixing the castle bolts at both end of top tad pole. Then only the load from winch can be released
which allows lifting frame to slide freely.
q. Bring down the lifting frame and lay it on ground, so that next plate assembly can be erected in a similar way.
r. Similar procedure shall be adopted for installing further plate assemblies.
s. While positioning other plate assemblies in a same floating channel, ensure that minimum three plate
assemblies are secured independently by castle bolts. The location of such plate assemblies would be both
end plate assemblies and middle plate assembly, in a floating channel.
Similar procedure shall be followed, for the ESP field where more than one floating channel are used.
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Sketch No. 51
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II. By Crane
Following are the brief guidelines for erection of collecting plates by crane.
a. Whenever crane is being used for erection of plate assembly, the installation should be done from ESP top.
Hence prior to starting the erection, availability of sufficient top clearance to be ensured, for easy lifting of
assemblies with its lifting frame.
b. Depending on the height of plate assembly being lifted and top clearance required, the crane capacity is to be
checked & ensured.
c. Ensure that no structural member foul in the way of collecting plate assembly lifting. In case any member fauls,
it may be removed temporarily, after consulting with the authorised person and it should be fixed back to its
original position immediately, after completing the installation work.
d. The lifting equipment (crane) and material handling items (e.g. wire rope, slings, rope pulleys, D - s h a c k l e s
etc being used for erection of plate assemblies), should be in good condition. All such items /equipment must
be tested for its safe load capacity, before it is brought to the site. Such test certificates must be made available
before they are used for work.
e. The wire rope should be in good and lubricated condition. The rusty ropes should not be used.
f. Always keep the material handling equipment (crane) at safe distance from ESP / lifting area.
g. Place the lifting frame near the erection spot and hook it to the crane.
h. Once all above preliminary arrangements are made, take no load trial run / dry run of lifting arrangement,
first with lifting frame only.
i. After successful dry run trials, as briefed above, plate assemblies should be shifted from stacked area. For
shifting the collecting plates assemblies from stacked area to erection spot, similar procedure can be
followed, as it was followed for shifting plate assemblies from assembly jig to stacking area.
j. Insert plate assembly in lifting frame and lock it properly, to avoid its falling down /slipping during its lifting.
The plate assembly should not be tied permanently with lifting frame, as it would result in problems while
removing the frame after plate assembly is fixed in its position in floating channel.
Note: COLLECTING PLATE INSTALLATION IS NOT ALLOWED WITHOUT USING LIFTING FRAME.
k. Once the plate assembly is inserted and locked in lifting frame, frame with plate can be lifted and can be taken
to the position where it is to be placed i.e. inside floating channel. Refer schematic sketch no. 050.
When lifting frame is in hanging position, there is a possibility of swinging or rotating the lifting frame. This
swinging or rotating of the frame would damage plate assembly. To control this, two manila ropes shall be
tied at both bottom corners of the lifting frame and with help of these ropes, swinging or rotating of frame
should be controlled.
l. If the swinging / rotation is beyond control (due to heavy wind flow) the erection of the collecting plates should
be kept under hold, till swinging or rotating, due to heavy wind, is within control.
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m. While placing the plate assembly inside the floating channel, little shaking to floating channel might be
required (may be not for first plate but for further plates)
n. After positioning the plate assembly inside floating channel, the plate assembly positioning should be
secured, by fixing the castle bolts at both end of top tad pole. Then only the load from crane can be
released which allows lifting frame to slide freely.
o. Then bring down the lifting frame, till such level that it becomes completely free from erected plate
assembly and then lifting frame should be taken outside ESP, from ESP top.
p. Then frame should be placed on ground, so that next plate assembly can be inserted in lifting frame
and it can be erected in a similar way, as briefed above.
q. Similar procedure shall be adopted for installing further plates assemblies.
r. While positioning other plate assemblies in a same floating channel, ensure that minimum three plate
assemblies are secured independently by castle bolts. The location of such plate assemblies would be
both end plate assemblies and middle plate assembly, in a floating channel.
Similar procedure shall be followed, for the ESP field where more than one floating channel are used.
Both the above points are to be checked in free hanging condition of collecting plate assemblies
i. Plumbness of Collecting Plates
a. To check the plumbness of collecting plates, put the plumb at two end locations in a respective field, as
shown in schematic sketch 052. Always check the plumbness at assembly edge of the collecting plate.
b. Ensure that plumbness of these two plates is correct i.e. within +/-4mm.
c. Fix a string line (horizontal) across the field width, at approx. 1000mm from bottom of the plate
assemblies. This string line should be touching to these two plumb.
d. Then measure the gap between the string line and collecting plate edge. If the gap is more than the
acceptable limits the shims of needed thickness can be inserted at top end of plate assemblies (i.e.
between top tadpole and floating channel cup) to bring the plate assemblies plumbness within
acceptable limit. Once plumbness of plate assemblies is brought within above acceptable limits, these
shims should be welded with floating channel cup, to avoid its dislocating & hence falling during ESP
operation.
e. The plumb readings are to be recorded along with the usage of shims.
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Once the plumbness & spacing of collecting plate is ensured, further items like alignment rake, tie bar (Bottom long
/short), keeper bar, upper tie bar, can be fixed. The schematic sketches of these parts are shown in sketch nos. 053
to 061.
Similar procedure shall be followed for alignment of collecting plate assemblies in other fields.
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Sketch No. 52
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Sketch No. 53
Sketch No. 54
Sketch No. 56
Sketch No. 55
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Sketch No. 60
Sketch No. 59
Sketch No. 61
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Sketch No.63
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Sketch No. 64
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Sketch No. 65
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Sketch No. 66
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a. Once top HV frame positioning and penthouse erection is completed, regitrode rapper rod can be
bolted to the top HV frame. While fixing the regitrode rapper rod to HV frame, correct verticality of
rapper rod should be maintained without any deviation and then it can be released for welding. While
welding, due care should be taken to avoid the disturbance to verticality. This can be done by
intermittent welding of rapper rod to HV frame.
After welding, again verticality and center distance between rapper rods to be checked and ensured.
b. After correct alignment of regitrode rapper rod, erection of suspension base should be done. While
placing the suspension plate, ensure that regitrode rapper rod is at the center of suspension plate. At
least 2 rounds of gasket rope should be provided between suspension base and roof plate. Also spirit
level of suspension plate must be ensured.
c. Then install the slide base, with hyperbolic tube. Here also spirit level of slide base plate should be
ensured along with center of regitrode rapper rod w.r.t. slide base plate.
d. Place the support insulator with its gasket on slide base plate. After installing support insulator, check
and ensure the spirit level of support insulator's top face. Also maintain the center of regitrode rapper
rod w.r.t. center of support insulator.
e. Then install insulator flange plate with gasket. After installing flange plate, once again check spirit level
of insulator flange plate.
f. While fixing insulator flange plate, check the direction purge air nozzles. The nozzles should be directed
towards support insulator inner face. Once the direction is fixed, tighten the nozzle nut from top and to
retain this position permanently, tack weld the nut, as shown in sketch 068.
g. After correct sprit level of support insulator top flange & correct orientation of purge air nozzle, fix the
springs with triple spring retainer plate and rapper rod nut.
h. Tighten the rapper rod nut slowly, so that HV frame load can be transferred on support insulators. To
have correct loading, tightening should be done simultaneously for all rapper rod nuts of the field. The
tightening should be in such a way that top HV frame is just freed from its temporary supports. Once top
HV frame is free from temporary supports, re-check alignment of HV frame (water level and its position
w.r.t. corner collecting plates as it was done while positioning top HV frame on temporary frame &
shown in sketch 075).
After getting correct alignment, regitrode fixing should be started.
HOLD POINT UNLESS UNTIL ALL CHECK POINTS, MENTIONED ABOVE ARE ENSURED, ERECTION OF
REGITRODE SHOULD NOT BE DONE.
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Sketch No. 67
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Sketch No. 74
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h. If any electrodes are found bend beyond 5mm, they should be repaired by either hammering (by wooden
mallet / fiber tip) or by heat & quench method.
i. After checking & ensuring the straightness of all regitrodes in a field, bottom frame shall be fixed to regitrodes
bottom.
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b. The clearance between regitrode pin and collecting plate surface should be measured at minimum three
locations (as described below) and these clearances must be maintained within the tolerances given below.
Please refer the attached schematic sketch no. 075 and record these clearances as per the format given in
table no. 2.
c. The above clearances must be checked for every pin of the regitrode. It is suggested that the GO-NO GO “T”
type gauges should be prepared and used to check the gap between regitrode pin and collecting plate
surfaces.
Such “T” gauges should be used at locations where easy assess is available.
The places where approach is not possible (e.g. the regitrode pins at the mid point of regitrode), the “eye-
balling” method can be used to check the alignment of regitrode pins. Here ESP inspector is to visually
imagine a straight line between correctly aligned pins at top and bottom of the regitrode. (The correctly
aligned pin means the pin tip is at the center of the regitrode and is within above-mentioned tolerance). Using
this imaginary straight line and radius of the regitrode tube as reference, any pins whose tips are estimated to
be out by more than 20mm w.r.t the reference line are considered to be out of tolerance. Such pins should be
straightened under guidance of ESP inspector.
d. The sufficient allowance is provided to accommodate the bow in collecting plate surface or bend of the
regitrode pipe. Hence, while doing field alignment, any additional considerations should not be given on this
point.
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Sketch No. 75
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e. The above field alignment readings are to be checked and recorded, for all fields of ESP, as per table no.2.
f. Also while checking the alignment between collecting plate surface and regitrode, following clearances
hould be checked and maintained-
i. Gap between hyperbolic tube and regitrode rapper rod- it should be minimum 121mm and
ii. Gap between hyperbolic tube and tip HV frame should be minimum 121mm.
In general, the electrical clearances between any sharp high voltage corner / edge and sharp grounded
corner / edge must be minimum 180mm.
HOLD POINT: TILL COMPLETION OF FIELD ALIGNMENT, FURTHER WORK CLEARANCES SHOULD NOT
BE GIVEN
Table No. 1: Recording Position of Regitrode w.r.t. adjacent collecting plates
Corner
At Top of Field At Bottom of Field
No.
No. 1 A B C D E F A B C D E F
No. 2
No. 3
No. 4
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Table No. 1: Format for recording collecting plate and regitrode alignment readings:
1 E F E F
2
10
11
12
13
14
15
16
17
18
Note: The above format of alignment reading recording is for 18 gas passages. However, in case of more gas
passage, similar format can be made and used.
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Sketch No. 76
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Sketch No. 77
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Sketch No. 78
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A. By Crane:
a. If sufficient space and suitable lifting arrangement i.e. crane is available, nozzle can be ground assembled
(either in one piece or in two pipes) and erected, along with GD screen.
b. If the nozzle is being assembled in two pieces, a care must be taken to maintain the matching dimensions (incl.
diagonals) of two pieces of nozzle. Otherwise these two pieces won't match, while erecting it.
c. While assembling / erecting, extra care should to be taken for carrying out panel's corner welding as well as
welding of nozzle with casing columns, as these are the areas highly prone for leakage.
d. Ensure correct installation of access door with its orientation as shown in reference drawing. Also weld the
rungs inside nozzle side plate, near access door area (top & bottom) of the nozzle. After nozzle erection,
depending on requirement, further rungs can be welded.
e. After ensuring sufficient space clearances, shift the assembled inlet nozzle to erection spot.
f. While shifting the nozzle, due care of safety (to man and nozzle) is to be taken, to avoid any accidents.
g. At erection spot, ensure that nozzle is kept on leveled surface and wooden sleepers.
h. Weld the lifting lugs on side of nozzle plate stiffeners, at appropriate location. These lugs should be welded on
nozzle topside. Ensure that lifting lugs size is as per referred nozzle assembly drawing. If lugs are welded on
nozzle plates, that may fail while lifting the nozzle to its position and may result the serious accident.
i. While lifting the nozzle, check dry run of crane, as briefed in collecting plate erection. Further lifting of the
nozzle assembly should be done only after ensuring dry run of crane.
j. While lifting the nozzle to its position, there is possibility of swinging / rotating the nozzle due to wind & / or
twists in the crane rope. To avoid & control it, tie a manila rope at all four-bottom corners of the nozzle. The
swinging / rotation of the nozzle should be controlled by these ropes, suitably.
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Sketch No. 79
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k. No man movements should be allowed below the area where erection work is in progress.
l. Once nozzle is fixed to its position, fitting and welding (at least stitch welding e.g. 400-300-400) should be
done. The crane should not be released, until nozzle fitting and its welding is completed.
m. When nozzle is hooked in the crane, crane shall not be switched OFF. Several times, if crane is switched OFF, it
may result in low air / hydraulic pressure which may cause serious accidents.
n. Once nozzle is erected and welded, the further items of nozzle like guide vanes / kicker vanes / ladder vanes
are to be fixed and welded as per drawing. While fixing these items, the sufficient care must be taken to
maintain the dimensions / angle of such items, as per reference drawing, as they play very vital role in gas
distribution of ESP.
o. To maintain the correct position with verticality of rapper rods, inlet GD rapper beam /connecting parts
should be welded after erection of the inlet nozzle with GD screen.
For erection of nozzles (Inlet and outlet), please refer its drawing send separately, along with the attached typical
schematic sketches nos. 079 to 090.
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Sketch No. 80
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Sketch No. 83
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Sketch No. 84
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Sketch No. 85
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Sketch No. 89
Sketch No. 88
Sketch No. 90
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Similar procedure should be followed for erection, fit-up and welding of other hoppers. For details of typical fit-up
and joints, refer above-mentioned sketches.
Once all hoppers are erected, other allied parts like RAV / Slide Gate / Expansion Joint etc. below hoppers can be
installed.
n. After erection of all hoppers of ESP, erection of hopper maintenance platform should be started (if applicable).
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Sketch No. 91
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o. For this purpose, refer the hopper level platform drawing sent separately.
p. While erecting hopper level platform, ensure that hopper and its allied parts like RVAL / Slide Gate / Dust
conveying system below hopper are free from platform. This is to ensure that hopper expansion is not
restricted during normal operation of ESP.
q. During erection of hopper level platform, take due precautions to avoid the damages to the parts installed
below hopper.
r. Ensure easy opening and closing of hopper access door, after installation of platform.
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Sketch No. 92
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Sketch No. 93
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While erecting monorail beam, safety precautions are to be taken to avoid the fall of monorail & / or its structure,
causing serious accidents / damages to material. Also man movements should not be allowed below erection area,
during erection of monorail & its structure.
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Sketch No. 94
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ELECTROSTATIC PRECIPITATOR Installation & Commissioning Manual
106
1) TRANSFORMER RECTIFIER MUST BE IN A LEVEL,
THE HIGH VOLTAGE CONDUIT MUST BE IN CENTER
OF H.V.DUCT.
Sketch No. 95
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Sketch No. 96
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Sketch No. 98
Sketch No. 99
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Sketch No. 67
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The above both checkpoints should be adjusted with the help of rapper studs. After correct alignment, tighten
rapper studs and secure it firmly with help of checknuts.
Similar procedure should be followed for all other rapper coils. While erecting the regitrode rapper coils, ensure that
all rapper coils are installed at same levels.
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Sketch No. 79
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Both above checkpoints should be adjusted with the help of rapper studs.
After correct alignment, tighten rapper studs and secure it firmly with the help of check-nuts.
Similar procedure should be followed for all other rapper coils of inlet GD screen rapping system.
While erecting inlet GD screen rapping coils, ensure that all rapper coils are installed at same levels.
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Description Location
Warning Sign for Access Door Above Access Door
Warning Sign for Hopper Access Door Above Access Door
Warning Sign for Duct Access Door Above Access Door
Warning Sign for High Access Door On TR Door
Thermax Monogram On ESP Top
Along with above warning signboards on ESP access doors, two more warning sign boards are to be
displayed in the plant control room. These warning signboards are attached with this as sketch no. 105 and
106. These are related to stoppage of ESP in case of higher CO level in process. Such warning boards should
be displayed near the ESP, ID fan and in plant control room, ESP control room. Also such boards should be
displayed in the local language which local people can understand.
+Mechanical Interlock System
The mechanical door interlocks are provided to ensure proper lock out of electrical system and de energisation of
HV transformer rectifier sets, before entering inside the ESP.
The system comprises the set of castle key & locks, such that unless TR control panel is switched off and transformer
rectifier set’s grounding switch is operated to earth position, the keys for various access doors are not available for
opening the doors.
These interlocks (i.e. keys / locks) are fixed at following locations –
a) On all access doors like casing, inlet nozzle, outlet nozzle, hopper, and penthouse.
b) On TR set in earth switch position and live position.
c) On TR set control Panel.
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B B B B
TRANSFER BLOCK - B1 & B2 B B B B
(KEY EXCHANGE ASSEMBLY)
B B DOOR INTERLOCK
BOX MOUNTED IN
CONTROL ROOM
X1 X2
TRANSFER BLOCK - C
X1 X2 X
TRANSFER BLOCK ‘A’ G3 G2 G1
G3 G2 G1 GROUNDING SWITCH
BW BW BW EARTH POSITION
LOCK ON GROUNDING
D3 D2 D1 SWITCH ENCLOSURE
BE BE BE
NOTES :-
1) LOCK SHOWN IN NORMAL OPERATING POSITION.
2) ABBREVIATIONS :-
BE - BOLT EXTENDED KEY RELEASED.
BW - BOLT WITHDRAWN KEY RETAINED.
- LOCK WITH KEY
- LOCK WITHOUT KEY
3) 5A ‘NO’ CONTACT TO BE PROVIDED FOR D1, D2 & D3 SOCKET TO BE MOUNTED ON TRCC PANEL.
+Operational Philosophy :
For accessibility to ESP internals through access door, following sequence to be followed.
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i. Switch of all TR control panels (e.g. 1, 2 & 3) & take out the keys D1, D2 & D3 from interlocks keys mounted on
TR control panels (Logic: Key released, bolt with drawn; key trapped bolt extended).
ii. Put these keys D1, D2, D3 in locks namely D1, D2 & D3 mounted on TR sets, near grounding switches. (Logic:
Keys trapped, bolt with drawn & key released, bolt extended) & operate the locks. Once the D key is trapped,
the grounding switch position can be changed to ground.
iii. Change the grounding switch position to ESP ground position.
iv. Extend the bolt by operating locks G1, G2 & G3 on grounding switch. (Logic: Key trapped, bolt withdrawn;
key released bolt extended). The keys from these locks (G) shall be now be released.
v. Put these ‘G’ keys in transfer block `A’ and lock the keys G1, G2 & G3 to operate these locks. Then ‘X’ key will
be released from the transfer block `A’.
vi. Put the `X’ key on lock `X’ in the transfer block `C’ & operate this lock. Now the keys ‘X1’ & ‘X2’ will be
released for transfer block ’B1’ & ‘B2’.
vii. Put the ‘X1’ & ‘X2’ key on lock ‘X1’ & ‘X2’ in the transfer block ‘B1’ & ‘B2’ respectively & operate this lock.
Now the keys for access doors (11 nos.) shall be released.
viii. Put these keys on access doors & operate the locks. This will allow operator to open the access door and
hence access to ESP inside.
ix. For switching on the TR set again, the above operations are to be carried out in reverse order of the action as
above. Following are the details of the keys / locks supplied for above briefed system.
7 Chain type door locks with out key for access doors B 11 Nos.
(On ESP)
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WARNING
WHEN THE KILN IS STOPPED OR KEPT UNDER HOLD, ENSURE THAT THE
ESP INLET DAMPER IS CLOSED WITHIN 2 MIN. WITH ABC CAP OPEN.
AND ESP I.D. FAN SWITCHED OFF.
THERE AFTER ESP PURGE AIR FAN TO BE SWITCHED OFF WITHIN 5 MIN.
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? WARNING
USE
EYE AND SKIN
HEAD AND NOSE
PROTECTION
HIGH VOLTAGE.
ENSURE THAT TR SETS ARE SWITCHED OFF
AND EARTHING SWITCHES ARE GROUNDED
BEFORE ENTERING ANY H.V. AREA.
ATTACH GROUNDING HOOKS ON ALL H.V.
COMPONENTS BEFORE ENTRY.
DO NOT REMOVE HOOKS UNTIL WORK IS
COMPLETED.
FOLLOW THE MECHANICAL KEY INTERLOCK
SEQUENCE, ENSURE THAT KEY INTERLOCK
IS NOT TAMPERED.
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WARNING
WHEN THE BOILER IS STOPPED, ENSURE THAT THE
I.D. FAN IS SWITCHED OFF AFTER 15 MIN. AND THEN
ESP PURGE AIR FAN SHOULD BE SWITCHED OFF AFTER 10 MIN.
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ONLY AFTER COMPLETION OF SUCCESSFUL LEAK TEST, FURTHER INSULATION APPLICATION WORK
SHALL BE STARTED.
Attached find few sketches (sketch no. 000 to 000) giving the brief idea of thermal insulation application work. In the
attached scheme, the air gap is provided between thermal insulation and cladding sheet.
Some schematic views of ESP assembly are attached with this to have an idea on the ESP assembly. This
can help user to understand the ESP components pictorial views, before its assembly and erection.
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Insulation Arrangement
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Insulation Arrangement
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Insulation Arrangement
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ELECTROSTATIC PRECIPITATOR
Chapter 10
Electrical Activities
Installation & Commissioning Manual ELECTROSTATIC PRECIPITATOR
Electrical Activities
Following are the electrical activities. Some of these activities are briefed as below.
A. Fixing of Support Insulator Heaters with thermostat
i. All support insulators are provided with heaters.
ii. While fixing the heaters for support insulators, refer the attached standard hook-up sketch no. 114.
iii. Use only PTFE cable for support insulator heaters.
iv. The heater should be placed around the support insulator, with uniform gap all around the support insulator,
as shown in attached sketch no. 114.
v. The heater body should not touch to support insulator or any other material, specially the materials that are
bad conductor of heat.
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1
Transformer
2 Rectifier Unit
(Representative)
Control 3
Panel
(Representative)
4
5 To Remote On/Off
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Cable for Power Connections: PVC Insulated, Power cables should not to be mixed with any
650 / 1100 V Grade, Aluminum Conductor, control cable (Sr.No. 3, 4 & 5)
1.
Armoured cable. (Size & details as per Project
Rating)
Cable for Primary Voltage Feedback : 2C or Feedback cables should not to be mixed /
3C2.5 sq. mm., PVC Insulated 650 / 1100 V bunched with Cables for Secondary Current &
2. Grade, Copper Conductor, Armoured Voltage feedback & Cable for Alarm &
Control Cable Annunciation, i.e. Cable No. 3 & 4. This can
be bunched with Power cable( Sr.No.1)
Cable for Secondary Current & Voltage These cables to be laid separately and not to
Feedback : 4C-1.5 sq. mm., PVC Insulated be mixed with power cables (Sr.No.1) or
3. 650 / 1100 V Grade, Copper Conductor, Primary Voltage Feedback cable (Sr.No. 2) or
Overall shielded with minimum 80% shielding any other cable having potential higher than
Armoured Control Cable 30 V.
Cable for Alarm & Annunciation : To be laid separately and not to be bunched
10C-2.5 sq. mm., PVC Insulated 650 / 1100 with Power Cable (Sr.No.1) or Primary Voltage
4. V Grade, Copper Conductor, Armoured Feedback Cable (Sr.No.2) or Cable for
Control Cable Secondary Current & Voltage (Sr.No. 3) or any
other cable having potential higher than 50 V
Cable for Remote On / Off (Optional) : These cables should not to be mixed /
3C-1.5 or 2.5 sq. mm., PVC Insulated 650 / bunched with any power cable &
5.
1100 V Grade, Copper Conductor, instrumentation cable.
Armoured Control Cable
Cable for Remote 4-20 mA Feedback These cables should not to be mixed /
Indication (Optional) : bunched with any power cables / control
4C-1.5 sq. mm., PVC Insulated 650 / 1100 V cable having potential higher than 30 V
6.
Grade, Copper Conductor, Overall shielded
with minimum 80% shielding Armoured
Control Cable.
Cable for Remote Alarm / Trip indication, HT Not to be mixed / bunched with any power
On / Off indications (Optional) *C-2.5 sq. cable & instrumentation cable
mm., PVC Insulated 650 / 1100 V Grade,
7.
Copper Conductor, Armoured Control Cable
(* No. of cores as required, Pl. refer the project
specific schematic drawing)
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ELECTROSTATIC PRECIPITATOR Installation & Commissioning Manual
IMPORTANT
These recommendations are important & mandated to enjoy a trouble free operation of the equipment.
Hence care shall be taken during installation stage itself. However for specific details, refer project
specific schematic drawings.
O. Cable Layout:
1. The power cables (cable No. 1) & signal cables (Secondary Current & Secondary Voltage feedback & Alarm
Cable No. 3 & 4) shall be run through separate cable trays. The signal cables can also be laid together with
other type of cables, provided that this is done in accordance with figure No. 1.
2. The Primary Voltage feedback cable (Cable No. 2) can be run alongwith Power Cable, However it shall not be
run alongwith Secondary Current & secondary Voltage feedback cable or Alarm & Annunciation cable.
3. If the distance according to figure No.1 can not be maintained, then the signal cables have to be placed in a
sheet metal cable duct with a cover.
4. The cable tray vertical layout order shall be descending, i.e. the cable tray consisting higher voltage cables
shall be at the top.
5. The crossing of the cable trays if required then cable tray having signal cables & cable tray having power
cables shall be at right angle as shown in figure No. 2.
P. Cable Tray
1. The metal cable tray shall be earthed. Cable trays shall be also bonded to cable channels or other wiring
drops, so that electrically the cable tray system is continuous.
2. Enclosed cable trays are preferable for low voltage signal wire cable tray. The enclosed cable tray provide
additional shielding from electric / magnetic field.
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Figure 1
≥300 mm
=30mm =100mm
Metal Cable Tray
Control Cables:
Power Cables: Signal Cables:
(Typically 230 V 110 V)
(Typically 415 V / 230 V) (Typically 24 V / 4-20 mA,
Relay Supply
Control Panel Supply Instrumentation cable)
Contactor Supply
Fan Motors Supply Feedback Cables
Pump Motors Supply Alarm Cables
Figure 2
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xi. During ESP operation, external electrical equipment like welding machines / other plant machinery's drives
etc. should not be connected to ESP earth grid or ESP control room earthing system.
xii. The weld connections of earthing flats must be cleaned and painted by anti rust paint.
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ELECTROSTATIC PRECIPITATOR
Chapter 11
ESP Pre Commissioning
Checklists
Installation & Commissioning Manual ELECTROSTATIC PRECIPITATOR
The pre commissioning checklists are attached, here after. All checkpoints given in this checklist are to be checked
jointly with Thermax's ESP supervisor, Customer' ESP supervisor and contractor. The report on this checklist should be
signed after completion of the checkpoints.
The ESP pre commissioning activities should not be carried out unless until attached checklist is completed and
signed off jointly.
152
ESP's Mechanical Completion Check Lists
Name of Customer:
153
Plant / Site Location:
Customer PO No.:
Thermax OC No.:
Name of Thermax Representative:
ESP BEARING
Bearing alignment inspection protocol [level (spirit & water), axial & diagonal measurements w.r.t. fixed bearing as per
1 bearing layout drawing] and its acceptance protocol.
Casing
Erection of ESP casing panel & column, top & bottom girder as per drawing w.r.t. ESP centerline and its inspection
1 protocol (for plumb, axial & diagonal measurements).
Inspection of weld joints. Kerosene leak test of all weld joints.. All weld joints should be free from for left out welding /
2
welding defects like blow holes, welding cracks etc.
Removal all temporary supports provided for casing erection / welding purpose, after ESP alignment and before ESP box
3 up.
1 Inspection of inlet nozzle assembly & its installation with perforated sheets as per drawing.
Inspection of weld joints. Kerosene leak test of all weld joints.. All weld joints should be free from for left out welding /
2
welding defects like blow holes, welding cracks etc.
1 Inspection of outlet nozzle assembly & its installation with perforated sheets as per drawing.
Inspection of weld joints. Kerosene leak test of all weld joints.. All weld joints should be free from for left out welding /
2 welding defects like blow holes, welding cracks etc.
3 Alignment of outlet nozzle inlet flange (plumbness and diagonal).
Installation & Commissioning Manual
Sl. Completion Date Checked & Witnessed by
Check Point Description
No. Field 1 Field 2 Field 3 THERMAX Customer
Hopper with its baffle plates and other accessories
1 Erection of hopper as per drawing with hopper baffle plates and inspection door.
Inspection of weld joints. Kerosene leak test of all weld joints.. All weld joints should be free from for left out welding /
2 welding defects like blow holes, welding cracks etc.
1 Inspection of floating channel arrangement for axial, diagonal measurements and water level.
2 Check all collecting plates are free from bows / local deformations.
3 Inspection of collecting plate assemblies for its diagonals and other measurement, as per drawing.
4 Check the tightness of fasteners used for collecting plates assemblies and its welding before collecting plate erection.
Check the straightness & plumb of installed collecting plate, in its free hanging condition. All collecting plates should be
5 straight in the tolerance of +/- 5 mm, either side.
6 Welding of all fasteners (Nut to bolt welding) used for collecting plates / its assemblies after alignment.
Regitrodes with its allied parts
Inspection of top HV frame erection and its alignment (level & positioning w.r.t. adjacent collecting plate rows). Ensure that
1
the regitrode rows (in gas flow direction) are in the mid-way of the adjacent collecting plate rows.
2 Check the straightness of all installed regitrodes, in its free hanging condition. All regitrodes must be straight.
Check the gap between collecting plate and regitrode, using GO / NO GO type gauge. All temporary locking / supports of
3 regitrode frame must be removed before gap checking. While checking the gap, top HV frame should be in free hanging
condition. Record all the deviations of this inspection and attach the records with this checklist.
4 Welding of all fasteners (Nut to bolt welding) used for regitrodes and its allied parts, after gap checking.
ESP Baffle Plates
1 Check installation of casing baffle plates as per drawing.
2 All baffle plate shall be seal welded with casing panel. No gap between baffle plate and casing side panel is allowed.
Support Insulator
1 Installation of support insulator installation and its allied parts.
2 Alignment of top HV frame, after support insulator loading.
ELECTROSTATIC PRECIPITATOR
154
Collecting Plate Rapping System
1 Alignment (verticality / plumb) of rapper rods.
Sl. Completion Date Checked & Witnessed by
Check Point Description
No.
155
Field 1 Field 2 Field 3 THERMAX Customer
2 Exposure of rapper plunger outside the rapper coil. The plunger should be projected 38mm (ONLY)
outside the coil, for effective rapping.
3 Alignment of rapper coils. All rapper coils must be in correct vertical position (plumb).
4 Grounding of the rapper rods.
5 Sealing of rapper rods, using hypalon boot and clamps.
Discharge Electrode Rapping System
1. Alignment (verticality / plumb) of rapper rods and double tapered rapper rods.
2. Exposure of rapper plunger outside the rapper coil. The plunger should be projected 38mm (ONLY)
outside the coil, for effective rapping.
4 Grounding of the rapper rods.
5 Sealing of rapper rods, using hypalon boot and clamps.
Mechanical Interlock Systems
1 Check correct interlocks are fixed on following locations -
a. TR set (Grounding Switch & Live Position Switch).
b. TRCC Panel.
c. Casing Access Doors.
d. Hopper Access Doors.
e. Penthouse Access Doors.
f. Inlet & Outlet Nozzle Access Doors.
2 Check Functioning of interlock system with individual keys & transfer blocks.
Penthouse with insulation
1 Installation of penthouse panels as per drawing and its seal welding.
2 Kerosene leak test of all seal weld joints.
3 Thermal insulation of penthouse top plate insulation from inside. The thermal insulation should not touch
to the shaft insulator. Proper cutting to be ensured around the shaft insulator.
Installation & Commissioning Manual
Sl. Completion Date Checked & Witnessed by
Check Point Description
No. Field 1 Field 2 Field 3 THERMAX Customer
Purge Air System
1 Check the location of purge air system, as per drawing. While installing the purge air system, ensure that
there is sufficient space available around the filter unit / blower / electric motor, for maintenance purpose.
2 Fixing of anti vibration pads and flexible connection(at inlet & outlet of blower) for purge air blower.
Monorail Structure with lifting equip.
1 1
Monorail installation, alignment and welding as per drawing
2 Welding of stoppers at both free ends of the monorail beam.
Installation & Commissioning Manual
Check the TR set oil BDV value. If BDV value is less than 50 kV, the TR oil re-filtration is to be bone, till
1
BDV value reaches more than 50 kV. This is to be done before TR set is erected on ESP top.
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Chapter 12
Pre Commissioning
Activities
Installation & Commissioning Manual ELECTROSTATIC PRECIPITATOR
Following are the pre commissioning activities, to be carried out in the sequence / parallel mentioned below.
Pre Commissioning Activities
+ Checking of cable continuity + Gas Distribution Test + Checking of TR set oil BDV
/megger for all power / control / value.
feedback cables
Checking of earth resistance
+ + Checking of TR panel wiring, as + Operational checking of hopper
per drawing heaters w.r.t. Thermostat setting
157
THERMAX LTD
ENVIRO DIVISION
PRECOMMISSIONING REPORT (ESP)
158
Gas Distribution Report Format
Format: T-EPD-SR-F-023
Customer:
Plant Location:
Date: Time: From Hrs To Hrs
Gas Passa ge
Approx. Height 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18
from bottom
8.5 m
7.5 m
6.5 m
5.5 m
4.5 m
3.5 m
1.5 m
0.5 m
Notes:
1 During test - The ID Fan current was Amps and ID fan inlet damper opening was %
2 During test - The FD Fan current was Amps and FD fan inlet damper opening was %
The above format is for 18 gas passage with 9m collecting plate height. Similar format should be modified for more number of gas passage and for higher collecting
3
plates.
As ESP GD test is an activity to be carried out in a confined space, following safety precautions must be followed
strictly while conducting the GD test
+The unit in which ESP is installed and for which gas distribution is to be conducted should be under shut down.
+The ESP hoppers must be evacuated and completely empty, if downstream equipment on which ESP is
installed was in operation before ESP's GD test. Before conducting GD test, ID and / or FD fans must be kept
ON till such time that ESP stack is visually clear. This would help to take away the dust settled in ESP's inlet &
outlet duct and also from ESP. During this period, rapping system of ESP should be kept ON. This is very much
essential for safety of the representatives conducting GD test.
+During GD test, inside temperature of the ESP should be always normal ambient temperature.
+No activity shall be continued during GD test period, inside downstream equipment on which ESP is installed.
+While conducting GD test, all power supply to ESP transformer rectifier sets and other auxiliaries like heaters /
rapping system / ash handling system should be switched off and its fuses shall be removed from safety point
of view.
+All TR sets should be in ground position. Also regitrode system should be in earthed position.
+All mechanical door interlocks should be in trapped position.
+ESP’s all inspection doors (casing / hopper / roof) should be tighten and closed properly.
+Ash handling system should be in OFF condition and its outlet should be closed to ensure that false air is not
entering through hopper bottom.
+In case of boiler ESP, boiler should be under de-pressurised condition.
+The persons present inside ESP should carry the communication tools for communication with CCR and out
side representatives, as and when required.
+The responsible plant authority must be available near, out side ESP inspection doors, to communicate
between representatives conducting GD test and Plant CCR.
+In case of emergency, ID fan tripping facility should be available with the co-ordination team, communicating
with the group conducting the GD test inside ESP.
II. Checking of cable continuity / megger for all power / control / feedback cables
+This is required to ensure that the cables used for ESP are in healthy condition without any defect.
III. Checking of earth resistance
+To ensure that the earth resistance of ESP earthing grid is below 1Ù.
IV. Checking of RDP & MTP panel (Resistance / Continuity / Matrix / Lamp Load / Operation)
+To check healthiness of RDP and its components.
+To check healthiness of MTP and its components, alongwith its functioning, as per requirement.
+To check rapper panel functioning.
+To set the lift of rapper plunger, for respective rapper coil.
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The BDV of TR set oil should be always more than 45KV. In case BDV value is less than 45KV, the TR set oil filtration is
to be done, till the BDV value is reached more than 50KV.
This activity must be done before TR set erection, to avoid additional work of bringing down the TR set on ground
and then again re erection of same, after oil filtration.
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PRECOMMISSIONING REPORT
Page 1of 7
Client:- Application:-
Client’s PO No.:- Thermax’s OC No:-
Format: T-EPD-SR-F-023 Rev.: 1
T/R SETS & TRCC DETAILS
Field 3
1. Remove all bushing external connections. Short the primary side bushings and secondary side
bushings separately.
2. For LT to Earth 1000V megger to be used and for HT to Earth 500V megger to be used.
3. Connect the megger between Primary to Earth, Secondary to Earth and Primary to Secondary.
4. The minimum value of insulation resistance should be as follows:
MINIMUM
DESCRIPTION REQUIRED (IN MO) FIELD 1 FIELD 2 FIELD 3
Primary To Earth (LT To Earth) 50
Primary To Secondary (LT To 500
HT)
Secondary To Earth ( HT To 100
Earth)
Note: Gap between electrodes = 2.5 mm and Minimum Required B.D.V = 50 kV (For mineral base oil)
Ambient Temp: - º C
Date:
Name:
Sign:
COMPANY: THERMAX CUSTOMER CONSULTANT
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PRECOMMISSIONING REPORT
Page 2of 7
Client:- Application:-
Client’s PO No.:- Thermax’s OC No:-
Note:-For healthy lamp load test, both the lamps should glow steadily.
Date:
Name:
Sign:
COMPANY: THERMAX CUSTOMER CONSULTANT
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PRECOMMISSIONING REPORT
Page 3of 7
Client:- Application:-
Client’s PO No.:- Thermax’s OC No:-
1. Isolate the ESP field from TR set HT bushing by removing the HT connection going to ESP Field.
2. The following test is to be carried out through a dimmer start or in test / manual mode only.
Field 3
Note: - For healthy TR set, Primary Current values should not exceed 6 amps for ratings upto 500mA
and 10 Amps for ratings upto 1500mA.
In case of excess primary current, the TR sets should be switched off and TR sets are to be
checked for abnormalities.
1. Connect the TR set HT bushing to Earth either by connecting a separate wire or by operating
grounding switch handle to earth position.
2. The following test is to be carried out through TRCC Panel only.
3. During this test Is setting should be kept at 25% of rated secondary current and shall be
increased gradually to 50%, 75% and 100%.
Pass & Field Sec. Current Primary Primary Secondary Secondary Remarks
No. (Is) set Point Voltage (V) Current (A) Voltage (kV) Current (mA)
Field 1
Field 2
Field 3
Note: -
1. TR Controller shall not sense any spark during this test.
2. mA setting and mA actual and mA meter readings should be within±5% t
Date:
Name:
Sign:
COMPANY: THERMAX CUSTOMER CONSULTANT
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PRECOMMISSIONING REPORT
Page 4of 7
Client:- Application:-
Client’s PO No.:- Thermax’s OC No:-
Date:
Name:
Sign:
COMPANY: THERMAX CUSTOMER CONSULTANT
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PRECOMMISSIONING REPORT
Page 5of 7
Client:- Application:-
Client’s PO No.:- Thermax’s OC No:-
MA Field 1 Field 2
Set P rimary S econdary Spark P rimary S econdary Spark
Point Voltage Current Voltage Current Rate Voltage Current Voltage Current Rate
(V) (A) (kV) (mA) (V) (A) (kV) (mA)
MA Field 3
Set P rimary S econdary Spark
Point Voltage Current Voltage Current Rate
(V) (A) (kV) (mA)
Date:
Name:
Sign:
COMPANY: THERMAX CUSTOMER CONSULTANT
165
ELECTROSTATIC PRECIPITATOR Installation & Commissioning Manual
PRECOMMISSIONING REPORT
Page 6of 7
Client:- Application:-
Client’s PO No.:- Thermax’s OC No:-
TEST RESULTS
Rapper Group Rapper Forward Reverse Row to Col. Lift Actual Remarks
No. No. for CE / Meggaring Meggaring Earth to Setting Lift
EE / +ve to Row / +ve to Col Earth (Inches) (Inches)
PDPL -ve to Col. -ve to Row
1
2
3
4
5
6
7
8
9
10
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14
15
16
17
18
19
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28
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30
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32
Date:
Name:
Sign:
COMPANY: THERMAX CUSTOMER CONSULTANT
166
Installation & Commissioning Manual ELECTROSTATIC PRECIPITATOR
PRECOMMISSIONING REPORT
Page 7of 7
Client:- Application:-
Client’s PO No.:- Thermax’s OC No:-
Rapper Group Rapper Forward Reverse Row to Col. Lift Actual Remarks
No. No. for CE / Meggaring Meggaring Earth to Setting Lift
EE / +ve to Row / +ve to Col Earth (Inches) (Inches)
PDPL -ve to Col. -ve to Row
33
34
35
36
37
38
39
40
41
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49
50
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62
63
64
Date:
Name:
Sign:
COMPANY: THERMAX CUSTOMER CONSULTANT
167
ELECTROSTATIC PRECIPITATOR
Chapter 13
Commissioning
Activities
Installation & Commissioning Manual ELECTROSTATIC PRECIPITATOR
168
ELECTROSTATIC PRECIPITATOR Installation & Commissioning Manual
Page 1of 3
Format: T-EPD-SR-F-025 Rev.: 1
COMMISSIONING REPORT
3. Application :
4. ESP Model :
5. Fuel used :
6. ESP Parameters
Field 1
Field 2
Field 3
169
Installation & Commissioning Manual ELECTROSTATIC PRECIPITATOR
Page 2of 3
Format: T-EPD-SR-F-025 Rev.: 1
9. Microtapper Panel
:
i) Make and Sl. No. :
ii) Model :
iii) Parameter Setting :
Group 01 02 03 04 05 06 07 08 09 10 11 12
No.
RTT in
min.
Lift in
inch.
E. Compressor :
i) Supply Voltage :
ii) Fluctuation, if any :
i) Air Conditioned :
ii) Pressurised :
iii) Dusty / Clean :
170
ELECTROSTATIC PRECIPITATOR Installation & Commissioning Manual
Page 3of 3
Format: T-EPD-SR-F-025 Rev.: 1
1) Performance :
2) Thermostat Setting :
3) Current Drawn in amps. :
Field 1
Field 2
Field 3
Enclosure(s) :
171
Installation & Commissioning Manual ELECTROSTATIC PRECIPITATOR
THERMAX LTD
ENVIRO DIVISION
PMT Complex, Behind PCMC Building
Mumbai-Pune Road, Pimpri
PUNE 411 003
ACCEPTANCE REPORT
Page 1 of 2
Format: T-EPD-SR-F-029 Rev 0
This acceptance report is between
The customer_________________________________________________________________________________
And
Thermax Limited,
Enviro Division,
Pune
(A) Regarding the supply, erection of ESP vide Customer’s Order
no.___________________________ and Thermax’s OC no. _____________ and commissioning
of Electrostatic Precipitator
Supply, erection and commissioning were according to the contract without reservation.
Supply, erection and commissioning were according to the contract with reservations. The
corrective work is listed under (f) still has to be carried out.
(C) Rejection of acceptance.
Repetition of acceptance is required after the corrective work as listed under (F) has been
carried out.
(D) The supply, erection & commissioning completed as per the milestones listed below :-
Completion Date
Delivery of equipment is completed
Commissioning
Warrantee starts
(E)
Participant Name Company Date Signature
1.
2.
3.
172
ELECTROSTATIC PRECIPITATOR Installation & Commissioning Manual
THERMAX LTD
ENVIRO DIVISION
PMT Complex, Behind PCMC Building
Mumbai-Pune Road, Pimpri
PUNE 411 003
ACCEPTANCE REPORT
Page 2 of 2
173
ELECTROSTATIC PRECIPITATOR
Chapter 14
Precautions
Installation & Commissioning Manual ELECTROSTATIC PRECIPITATOR
Following are the safety precautions to be taken for smooth functioning of ESP.
2. Safety Measures:
Since Agro Waste Fired Boilers have potential fire hazard at areas like ESPs, it is essential to follow the certain safety
measures during operation of the boiler & ESP, as following:
a. Rotary Air lock Valve:
RAVs to be kept running whenever the flue gases are passing through the ESP irrespective of the TR sets are
On or Off. Zero speed switches are provided to all RAVs. The trip contact of the RAVs will be wired for tripping
the respective TR set. Further potential free contact of trip relay will be provided in the Aux. control panel (ACP)
to hook up with Boiler control panel. Necessary alarm & indications to be provided in ACP. The Boiler is to be
tripped / stopped after time delay of two hours if the RAV fault is persisting. The customer should ensure the
RAV blade clearance less than 0.4 mm for MS rotor with adjustable tips (not applicable for CI rotor RAV). A
periodic check should be done at an interval of 3 months for the same. The RPM of RAV should be maintained
between 10 to 15 only & the minimum size should be as per point C.11.
b. Dust Conveying System:
The dust conveying system should also be in service whenever RAVs are running. In case if the Dust conveying
system trips / stops then all the TR sets & all RAVs will be tripped. Potential free trip contact of dust conveying
system to be taken from Customer's control panel & to be wired for TR set RAV tripping long with fault
annunciation (Audio visual alarm & indications) in ACP. The dust settled in hopper should be evacuated
through the bypass chutes. However, the bypass chutes should not be opened up during Boiler running
because that will cause sudden in-rush of air inside the ESP and it may result total meltdown of the ESP
internals.
For pneumatic ash conveying system more care should be taken, since historically, it is more maintenance
prone and once the system gets choked, not very easily normal condition is retrieved. Therefore, prolong time
for non-functioning of pneumatic ash conveying system will pose more danger for fire hazard at hoppers of
particularly biomass-fired boilers. Routine maintenance is must with proper spares back up in order to keep
the system available and operational.
174
ELECTROSTATIC PRECIPITATOR Installation & Commissioning Manual
3. ADDITIONAL PRECAUTIONS:
The ESP hopper discharge flange size is always more than or equal to 350mm (Refer point no C.11 also). The
size of dust conveying system should not be less than 350 mm. A note is to be mentioned on ESP GA Drg. for
information to customer. A caution note to be mentioned in the Control logic & ESP operation & maintenance
manual about the high carbon content in the flue gas and effect of the same on ESP.
ESP hopper doors to be opened only after ensuring that the I.D. fan is shut down. A caution note mentioning
this is to be mentioned in Control logic & ESP operation & maintenance manual. Start interlock for ID fan shall
be provided such that ID fan should not start unless all the access doors is closed.
175
Installation & Commissioning Manual ELECTROSTATIC PRECIPITATOR
Provide ID fan start interlock such that: ID fan should not start unless all the dust discharge equipment below
hoppers such as RAVs, Screw conveyors, etc are 'ON'. Here slide gates 'open' position must be ensured
manually.
Customer should replace all the access door gaskets at every shut down when the doors are opened. This is
required to prevent any fresh air ingress through the doors.
The rapping must be kept 'ON' when ID fan is running irrespective of the ESP is charged or not. The RAV rpm
should be kept between 10 to 15 rpm to increase the dust discharge efficiency.
Hoppers shall have larger poking holes of minimum size 100 NB. Hopper shall be provided with SS 304 2D /
3D finish liners for bottom 1/3rd portion for all ESPs on Bagasse fired boilers.
The bypass chutes shall be provided with blind flange. Also the size of bypass chute shall be minimum 350mm
dia. The bypass chutes shall not be provided for trough hoppers.
Two No. Of pneumatic vibrators should be provided for each hopper from outside. The vibrators
1.
should be mounted in bottom 1/3rd of the hopper on opposite sides.
2. RAV of size 400 should be provided.
5. Hoppers shall be provided with SS 304 2D / 3D finish liners for bottom 1/3rd portion.
The bypass chute shall be provided with blind flange. (Minimum size 400-mm dia.) except for
6.
trough hoppers.
7. Hoppers shall have large poking holes of minimum 100 NB size to avoid dust bridging
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ELECTROSTATIC PRECIPITATOR Installation & Commissioning Manual
Equipment / Instrument
Sr. No. Signal Action
Parameter
Alarm & Indication in ACP. Trip respective TR SET.
Rotary Air Lock valves provided
Trip signal is taken from zero Signal to DCS
below I&II Field HoppersTrip
1. speed switch(This zero speed
switch is fixed near Rotary Air Lock
Valve Driven end )
Rotary Air Lock valves - Over load Alarm & Indication in ACP. Trip respective TR SET.
2.
relay Trip. Signal to DCS
If RAV faults persist for 2 hrs. Potential free contacts of Trip relay Trip Boiler.
will be provided in Signal to DCS
3.
ACP for alarm & indication + tripp
signal to Boiler.
Dust conveying system shall be Potential free contact for tripping All TR SETS, all RAV
4. ON all the time. If dust conveying the all TR SET, all RAV. shall trip.
system trip/stopped.
Hopper Heater (provided to keep Alarm &Indication in ACP. Trip Hopper heater.
the ash hoppers hot to increase Signal to DCS
5. the flowability of ash- Normally,
used to be started before 4 hrs of
Boiler start up) Temperature High.
RTD to be mounted in each Alarm & indication in ACP, Trip respective TR SET.
6. Hopper, with TIC in ACP. Hopper Potential free contact for tripping Signal to DCS.
Temperature Very High the Boiler. Trip Boiler.
Transformer Sets (T.R.SET) Trip. Alarm &Indication in TRCC. Signal to DCS
7.
Potential free contact to DCS.
Hopper Level High.(Level probe Alarm &Indication in ACP. Trip respective TR SET.
provided at about 60%of total Immediately Trip the Signal to DCS
8. hopper height distance below the corresponding Transformer sets.
collecting plates ) Potential free contact in ACP for
DCS signal.
Hopper Level High alarm persists Potential free contacts in ACP to Trip Boiler.
9. for 1 hr wire the same for Boiler Signal to DCS
Tripping/Stopping.
In case Inlet temp. Sensed by TE Alarm & Indication in ACP, Trip respective TR
increases above set point. potential free contact for DCS Sets. Signal to DCS
10.
TE to be mounted in the inlet duct signal
of ESP.
177
Installation & Commissioning Manual ELECTROSTATIC PRECIPITATOR
It is advisable to connect all these signal to clients PLC/DCS, so that ESP Performance history as a ESP LOG
SHEET will be available in DCS.
178
ELECTROSTATIC PRECIPITATOR
Chapter 15
Safety Risk Assembly
for ESP Activities
Installation & Commissioning Manual ELECTROSTATIC PRECIPITATOR
179
RISK ASSESSMENT FOR ESP ( ELECTROSTATIC PRECIPITATOR) INSTALLATION
180
Safety Risk Assessment Document (ESP) No.: TL/ENV/ESP/Safety/001 Rev 0
Sl.
Activities Hazards Safety Precaution Responsibility
No.
a) Fall / slip of objects due to inadequate a) Use of PPEs like safety shoes, Hand gloves, Safety helmet Contractor & Customer
handling facilities b) Use of catagorised skilled personal Contractor & Customer
c) Safety introduction to all workmen & supervisors. The emergency contact
nos.,like Fire / Ambulance / Nearest Hospital / Security are to be made Thermax Engg.
available at all locations like site office / ground assembly area / erection
1 Unloading of area and also with site engineers / contractor supervisors
materials
b) Damages to the material due to not a) Safety instructions are to be followed during unloading of material. Thermax Thermax HO
following the safety instructions HO to send the safety instruction / risk assessment to sites well in advance.
b) Special safety / unloading instruction for collecting plates / emitter electrodes Thermax HO
/ support & shaft insulator / GD screens are to be circulated in advance.
c) Unloading instructions to be sent to site alongwith material. Thermax HO
ELECTROSTATIC PRECIPITATOR
c) Use of inadequate / wrong / undersize a) Use of correct size tools / correct capacity equipment for unloading the Contractor & Customer
material handling tools / equipment material; b)
a) Caught in between finger / foot injuries a) Use of PPEs; b)Follow safe material handling procedure; c) Use of proper Contractor & Customer
2 Storage / stacking material handling tools & tackles. / Use of catogarised skilled manpower /
of materials Use of correct tools / tackles / equipment for stacking the material
b) Fall of ESP material due to improper Use of suitable wooden sleepers, supports to avoid fall of stacked material. / Contractor & Customer
stacking, resulting in to accidents and Provide sufficient cover like temporary shed / tarpaulin to avoid the damages
damage to material to the material due to dust / rain.
c) Gas Storage facility LPG / Acetylene gas storage facility Contractor & Customer
All lifting material to be tested for their capacity before taking them in to use. Contractor & Customer
a) Breakage of chain sling / wire rope
Test certificate to be obtained from competent person. This is required as
& manila rope
per factories act 1948.
Shifting of materials
3 to site (Manual &
mechanical material c) Breakage of chain sling / wire rope All lifting material / tools / tackles shall be checked periodically, for any Contractor & Customer
handling equipment) & manila rope defects those arises during its use and stop its using if any defects found
i) Verification of loading point of hydra / chain pulley block / test certificates Contractor & Customer
b) Overloading of equipment during of wire ropes
lifting
ii) Identification / marking of weight on the job being lifted Contractor & Customer
Installation & Commissioning Manual
Sl.
Activities Hazards Safety Precaution Responsibility
No.
c) Inadequate lift hook position ( Vertical Proper lifting hooks are to be considered during design stage and Contractor & Customer
& horizontal lifting) same to be provided during fabrication stage. (Check the marking on
the component in place
Shifting of materials of lugs.)
iii) Alcoholic consumption strictly prohibited during working hours. at site Contractor & Customer
operating crane and other material handling equipment / vehicles.
a) Unsafe practice of cable laying from a) All electrical cables are to be laid down safely either underground or Contractor & Customer
Electrical connection electrical panel to site distribution board. overhead and through pipe conduit.
4 for erection / ground b) Safety sign to be displayed for caution, at all such location.
assembly work a) Main distribution board ELCB, of sufficient capacity / rating, should Contractor & Customer
b) Unsafe practices of cable connections
be provided with TPN facility, near ESP erection site.
/ joints (hand lamps / tools / earthing)
b) Cable extension boards should be used. Contractor & Customer
c) Proper earthing should be provided for all electrical appliances being used Contractor & Customer
at site. Earthing points to be checked and ensured.
d) All welding machines / other electrical tools are to be tested at site (for Contractor & Customer /
megger & current) for correct current rating. Thermax
e) Proper safe cover to be provided to all electrical appliances / boards Contractor & Customer
specially in rainy season
f) provide sufficient fire extinguisher / sand buckets near main DB & welding
machines.
a) Uneven ground floor resulting slipping Level the ground by back filling the soil at least 8-10 days prior to ground
of material during assembly assembly work, to avoid delay in activity. Contractor & Customer
5 Ground assembly
work b) Welding sparks / fire /electrical shock a) Do not keep the flammable items (e.g. acetylene or LPG cylinders) near Contractor & Customer
causing fire hazards and damages to welding / cutting area.
material & leading to accidents b) Ensure the availability of fire extinguisher (CO2 or water / sand) or sufficient Contractor & Customer
water while doing the hot work nearby flammable material.
c) Ensure that the surfaces being welded are in dry condition. Also ensure that Contractor & Customer
the welder is not over sweated which can cause accident due to electrical shock
ELECTROSTATIC PRECIPITATOR
181
Sl.
Activities Hazards Safety Precaution Responsibility
No.
182
c) Accidents due to gas cutting / back a) Use of correct size cutting sets / cutting nozzles / back fire arrestor to be done. Contractor & Customer
fire / leakage of gas The gas cylinders are to be kept in vertical position, preferably in cylinder trolley.
Use of tested gas regulators with pressure gauges. Use the cylinders with guard.
5 Ground assembly Use proper hose pipe with standard colour coding and proper hose clamps to be
work used to connect the hoses.
b) Ensure the availability of fire extinguisher or sufficient water while doing the Contractor & Customer
hot work.
d) Accidents due to grinding sparks / eye Use of PPEs like hand gloves, safety goggles, electrical appliances with proper Contractor & Customer
injuries / fire / electrical shock earthing should be used.
e) Accidents causing to hand / finger Use of PPEs like hand gloves, safety goggles, proper tools like wooden Contractor & Customer
injuries during hammering / fitting sleepers, packings while doing the work.
f) Accidents due to in-sufficient temporary
supports to component causing fatal Use of sufficient support to avoid falling of component being assembled.
accident / damages to material
Ground assembly a) Fall of derrick / fall of lifting Adequate safety precautions like are to be taken - i) Guy ropes, ii) Verticality of Contractor, Customer,
ELECTROSTATIC PRECIPITATOR
6
work arrangement &lifting support derrick after loading, iii) Barricade the area while erecting derrick, iv) Experienced Thermax Engineer
arrangement & skilled riggers need to be engaged for derrick erection
a) Use of PPEs Contractor & Customer
b) Hand and foot injuries b) Follow safe material handling procedure Contractor & Customer
c) Use of proper material handling tools & c) tackles Contractor & Customer
d) Periodic safety training Contractor & Customer
Contractor & Customer
c) Accidents resulting in loss of man-days a) Provide adequate space for ground assembly of components.
and affecting equipment performance b) All ground assemblies to be done on proper leveled platform Contractor, Customer,
due toinadequate facility / arrangement Thermax Engineer
for material being lifted c) Use of proper lifting tools / tackles (with test certificates) Contractor & Customer
d) Adherence to the sequence of erection, alignment & welding Contractor, Customer,
Thermax Engineer
e) Ensuring sufficient lifting lugs for material being lifted Contractor & Customer
f) Ensure the dry run of the material handling equipment, before lifting the
material.
d) Fatal accident due to not using proper a) Under any circumstances, use of lifting frame & assembly jig must be ensured, Contractor, Customer,
lifting frame / tools / locking arrangements as per Thermax drawing. Thermax Engineer (Not
for material being lifted. following the safety
precaution, will affect the
ESP completion schedule
and performance of ESP.)
Installation & Commissioning Manual
Sl.
Activities Hazards Safety Precaution Responsibility
No.
e) Accidents due to lack of knowledge of a) The work group / supervisor should be briefed on the equipment knowledge Contractor, Customer,
equipment & poor communication / / activity knowledge. Thermax Engineer
inadequate work procedure & wrong b) For effective communication, arrange meeting for allocating responsibilities, Contractor, Customer,
6 Ground assembly erection sequence before commencing the work. Thermax Engineer
work c) Follow the sequence of mechanical installation.
d) Always responsible, authorised person must be available outside ESP, while Contractor, Customer,
workmen are working inside ESP. Thermax Engineer
a) Fatal accident / permanent disability a) Use of PPEs i.e. safety belt, helmet, safety shoes, hand gloves, safety goggles Contractor & Customer
etc.
b) Provision of proper scaffolding and ladder arrangement for working people Contractor & Customer
Installation & Commissioning Manual
at higher elevation.
7 Working at height b) Inadequate facility to reach at high a) Provide proper ladders to have approach to ESP columns / girders after Contractor & Customer
elevation, resulting into fatal accident erection. Use of fall arrestor for the working men at height.
b) Provide the lugs / supports on upper end of material being erected, so that Contractor & Customer
workmen can hook the safety harness while doing the work at high elevation.
c) Falling of tools / scrap - debris / a) No man movements, on ground / lower elevation, is allowed while any work Contractor & Customer
erection material (cutting / erection / material lifting / fitting) is going on at higher elevation.
b) All tools, being used at high elevation should be tied to job, with proper Contractor & Customer
chain, to not to allow to fall.
c) Provide the safety barricade tapes below working area to avoid the entry of
personal.
a) Physical fitness certificate to be obtained by authorised physician Contractor & Customer
d) Physical fitness / Poor vision workmen
b) Continuous restless work, which can affect workmen fitness, should not be Contractor & Customer
while working at height
allowed.
e) High wind flow causing disturbance in a) No work should commence, if heavy windflow affects in safe work conditions Contractor & Customer
work activity which results in accident
a) Ensure that the fuses from incomer panels and put the board of 'MEN AT Contractor & Customer
WORK. DO NOT SWITCH ON'.
8 Electrical Installation a) Improper lock out while working with b) For cable termination, the sequence shall be followed from main equipment Contractor & Customer
electrical live power supply during to supply point e.g. MCC / ACP to TRCC or TRCC to TR set. First TR set cable
installation / sequence of cable termination termination to be done followed by termination at TRCC and then at MCC / ACP.
b) Improper way of cable pulling a) While pulling the cables vertically upwards, sufficient workmen to be Contractor & Customer
deployed at various elevation with use of PPEs.
b) Proper /suitable arrangement to be ensured for pulling / dropping the cable. Contractor & Customer
a) Cable extension boards should be used. Contractor & Customer
c) Unsafe practices of cable joints
b) Proper earthing should be provided for all electrical appliances being used Contractor & Customer
(hand lamps / tools / earthing)
at site.
ELECTROSTATIC PRECIPITATOR
183
Sl. Activities Hazards Safety Precaution Responsibility
No.
184
a) No hot work to be done near electrical / instrument items, without putting Contractor & Customer
8 Electrical Installation d) Hot work (gas cutting / welding / heating etc.) proper cover on the items.
near electrical / instrumentation items like cables, b) Follow the installation sequences Contractor, Customer,
TR sets, Heaters, Level sensors etc. Thermax Engineer
c) Equipment awareness to be given to the workmen Contractor, Customer,
Thermax Engineer
Accidents due to improper crimping / workman Use of proper tools / tackles for cable termination / crimping. All cable are to
be terminated with use of lugs. All activities are to be done by categorized
ship / inadequate measuring instruments
skilled personal. Proper and calibrated measuring instruments are to be
provided while doing the work.
e) Injury to fingers / hands while removing cable a) Use of PPE must be ensured Contractor & Customer
insulation / armour with knife b) Use of non-standard tools like knife / cutter must be stopped. Contractor & Customer
f) Operation of panel switch with naked hands i.e. a) Replace the damaged panel handles Contractor & Customer
switching ON panels without using panel handles b) Use the suitable insulated tools like, if required in urgency Contractor & Customer
9 Pre-Commissioning / a) Serious accident due to inhalation of dust a) Proper work permit must be obtained ensuring power lock out / men on Contractor, Customer,
ELECTROSTATIC PRECIPITATOR
Commissioning inside ESP (Confined Space) during ESP GD test work at panels, before entering ESP inside. Thermax Engineer
Activities b) Use of PPEs must be ensured before entering inside ESP for GD test. Contractor, Customer,
Thermax Engineer
c) Before entering inside ESP, ensure that there is no dust passing through ESP. Contractor, Customer,
This can be done by running the ID fan till stack is clean visually, before Thermax Engineer
entering inside ESP.
d) Proper communication tools must be used while conducting GD test. Contractor, Customer,
Thermax Engineer
e) Always responsible, authorised person must be available near, outside ESP, Contractor, Customer,
while conducting the GD test. Thermax Engineer
b) Hazards associated with electrical, Proper work permit must be obtained ensuring power lock out / men on work Contractor, Customer,
instrumentation, mechanical works i.e. entry in at panels, before entering ESP inside. Thermax Engineer
confined space (narrow area inside ESP),
non availability of interlocking system & improper
communication for the work activity
c) Serious accident due to poor illumination Sufficient illumination of 24V / 100W lamps are to be provided. Minimum two Contractor & Customer
inside ESP (confined space) lamps must be provided per group, out of this 1 must be used as stand by
Installation & Commissioning Manual
Sl. Activities Hazards Safety Precaution Responsibility
No.
9 Pre-Commissioning / d) Chances of explosions inside ESP i.e. due to a) Install CO analyzer. ESP TR sets tripping interlocking to be incorporated if Contractor & Customer
Commissioning CO level is more than 2%
CO accumulation inside ESP / carry over of
Activities
uncontrolled, unburned inside ESP / improper b) In case if ESP ID fan is tripped for any reason, ESP purge air blower should Contractor & Customer
sequence of plant start up or shut down - All be switched OFF immediately.
resulting into ESP internal damages / ESP
b) Arrest all false air leakages inside ESP which supply oxygen to the fire. The Contractor & Customer
damage / Fatal Accident / Heavy losses to
sources of false air leakages might be from Rotary Airlock Valves, Inspection
property Doors, Hopper By-pass chute
Installation & Commissioning Manual
Inhalation & Exposure of dust, mist, fumes, a) Wear suitable PPEs Individual
10 Working in
gaseous
hazardous zone b) Before entering around / inside equipment, measure hazardous gases (CO) Individual (Customer to
level and carry the instrument till person comes out of hazardous zone. give CO analyzer)
High noise levels Use of ear muff / ear plugs Individual
185
ELECTROSTATIC PRECIPITATOR
Chapter 16
Stack Sampling
Procedure
Installation & Commissioning Manual ELECTROSTATIC PRECIPITATOR
Objective: This procedure is prepared to measure the operating performance of the Electrostatic
Precipitator (ESP) in order to check & establish ESP's actual performance verses its design Reference
Standard: - IS: 11255, 1985
Procedure:
Sampling and Measurement of the Operating Parameters
1. For the purpose of measurement of the operating parameters, iso-kinetic sampling method shall be carried
out at the locations identified prior to testing. The sampling test shall be carried out at the inlet and outlet of
the ESP simultaneously.
2. Where there are more than one ESPs for a single boiler or down stream equipment, the readings of each ESP
shall be taken and added for arriving at the total volumetric flow of the unit, unless the readings are taken in
the common duct or stack.
Similarly the dust concentration and gas temperature shall be taken by average of the separate gas passes.
The location of the sampling points shall be selected at inlet duct or stack, in such a way that there is sufficient
straight length in up stream or down stream of the ESP.
From sampling point, preferably 8 times duct diameter at down stream and 2 times duct diameter at up
stream is available. The flow disturbances like bends, expansion /contraction of ducting, dampers etc. should
not be in the straight length of duct as briefed above. Attached please find a schematic sketch nos. 107 & 108
giving the location of sampling ports at ESP inlet and outlet duct, along with brief guidelines.
In case, if such locations are not possible due to congested duct layout, the sampling port locations are to be
decided mutually with Thermax Ltd., Enviro Division.
3. The following are the minimum parameters to be measured during testing, to determine the ESP performance
At ESP Inlet
a. Flue Gas Temperature (in C)
b. Flue Gas Velocity (in m/sec)
c. Flue Gas Volumetric Flow (Am3/sec) Calculated gas flow x cross sectional area)
d. Dust Concentration (gm/Nm3)
e. Moisture content in flue gas (in % vol. / vol.)
186
ELECTROSTATIC PRECIPITATOR Installation & Commissioning Manual
Inlet Dust
Temperature in Gas Flow in Outlet Emission
Concentration
Sl. No ºC (At ESP inlet) AM³/hr in mg/NM³
in gm/NM³
Design Actual Design Actual Design Actual Design Actual
1.
2.
3.
Avg.
187
Installation & Commissioning Manual ELECTROSTATIC PRECIPITATOR
188
ELECTROSTATIC PRECIPITATOR Installation & Commissioning Manual
189
ENVIRO DIVISION
Chapter 17
List of Two Years
Operating Spares
Installation & Commissioning Manual ELECTROSTATIC PRECIPITATOR
For quick response please mention our equipment OC No. in the purchase enquiry.
190
ENVIRO DIVISION
Whome to contact
In case of problem
Installation & Commissioning Manual ELECTROSTATIC PRECIPITATOR
CHENNAI REGION
THERMAX LIMITED, 312, ANNA SALAI, TEYNAMPET, CHENNAI-600018.
TEL:044-24353831(4LINES) FAX:044-24353841
DELHI REGION
THERMAX LIMITED, 9, COMMUNITY CENTER, BASANT LOK, NEAR PRIYA CINEMA, NEW DELHI 110057.
SERVICE MANAGER TEL:011-26145319 FAX:011-26145311
REGIONAL OFFICE KOLKATA REGION
THERMAX LIMITED, AZIMGANG HOUSE, 5TH FLOOR, 7, CAMAC STREET, KOLKATA.
TEL:033-22826711/12/13 FAX:033-22826796
MUMBAI REGION
THERMAX LIMITED, DHANRAJ MAHAL, CHATRAPATI SHIVAJI MARG, COLABA, MUMBAI- 400039.
TEL : 022-22045391 FAX:022-22040859
CHENNAI REGION
THERMAX LIMITED, 312, ANNA SALAI, TEYNAMPET, CHENNAI - 600018.
TEL:044-24353831(4LINES) FAX:044-24353841 Email:ssrinivasan@thermaxindia.com
DELHI REGION
THERMAX LIMITED, 9, COMMUNITY CENTRE, BASANT LOK, NEAR PRIYA CINEMA, NEW DELHI 110057.
CORPORATE REGIONAL TEL:011-26145319 FAX:011-26145311 Email:glal@thermaxindia.com
MANAGER KOLKATA REGION
TH
THERMAX LIMITED, AZIMGANG HOUSE, 5 FLOOR, 7, CAMAC STREET, KOLKATA.
TEL:033-22826711/12/13 FAX:033-22826796 Email:amukherj@thermaxindia.com
MUMBAI REGION
THERMAX LIMITED, DHANRAJ MAHAL, CHATRAPATI SHIVAJI MARG, COLABA, MUMBAI 400039.
TEL:022-22045391 FAX:022-22040859 Email:fbacha@thermaxindia.com
THERMAX LIMITED, GREEN HOUSE, 148, MUMBAI-PUNE ROAD, PIMPRI, PUNE - 411 018.
SERVICE MANAGER TEL:020-27426013
HEAD OFFICE Email: jagdish.dulange@thermaxindia.com, prakash.mahale@thermaxindia.com
adutta@thermaxindia.com
THERMAX LIMITED, ENVIRO DIVISION, PMT COMPLEX, BEHIND PCMC BUILDING., MUMBAI-PUNE ROAD,
DIVISIONAL HEAD PUNE 411 018.
TEL:020-66122999 FAX:020-27426532 / 33
191
X
THERMAX LIMITED
ENVIRO DIVISION
PMT Complex, Behind PCMC Building, Mumbai - Pune Road, Pimpri,
Pune - 411018, Maharashtra, India.
Phone : 020 27475941, Fax : 020 27426532, Web: www.thermaxindia.com
In view of our constant to improve the quality of our products, we reserve the right to alter or change specifications without prior notice.
Doc. No. T-ENV-DE-M-007 RO. DT. 01.06.2007