Station: NTPC- Simhadri

BHEL Ref No.PS-DC-186-500-0043

NTPC Ref no SIM/1/TS/1/ 43

Plant area: BOILER

PROCEDURE FOR COMMISSIONING OF ESP
SLNO
LIST OF CONTENTS
1.0

PLANT DETAILS

2.0

OBJECTIVE

3.0

PROPOSAL

4.0

SERVICES REQUIRED

5.0

SAFETY PERECAUTIONS

6.0

EMERGENCY PROCEDURE

7.0

STATE OF THE PLANT

8.0

METHOD

9.0

COMPLETION CRITERIA

Sheet 1 of 19

Station: NTPC- Simhadri

BHEL Ref No.PS-DC-186-500-0043

NTPC Ref no SIM/1/TS/1/ 43

Sheet

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Plant area: BOILER

PROCEDURE FOR COMMISSIONING OF ESP
SL.NO

STATUS

1.0

PLANT DETAILS

1.1

Four numbers of ESP for each 500MW is provided for precipitating of

all dust emanating from the boiler flue gas. Two ESPs are located in the
left and two ESPs are located in the right of the boiler flue gas path
before ID fans. Each ESP is further divided into eight fields per flue gas
path. Ref : O & M Manual for ESP schematic diagram.

1.2

Parts of Precipitator (Ref. O & M MANUAL)

1.2.1

Mechanical system:
Precipitator Casing made of pre-fabricated panels. The casing is
provided with inspection doors with gas tight seal construction. The roof
carries the precipitation internals, insulation housing transformer etc.
The Casing support allows for free thermal expansion of the casing
during operation.

1.2.2

Hoppers: The hoppers are adequately sized to hold the ash. Baffles are
provided in each hopper to avoid gas leakage. Thermostatically
controlled heating elements are arranged at the bottom of hopper portion
to ensure free flow of ash.

1.2.3

Gas distribution system: Even distribution of gas over the entire cross
section of ESP is achieved by guide vanes, splitters and screens
provided in the inlet funnel of the ESP.

1.2.4

Collecting electrode system: The collecting plates are made of 1.5mm

cold rolled mild steel plate and shaped in one piece by roll forming. The
collecting electrode has unique profile designed to give rigidity and to
contain the dust in a quiescent zone free from re-entrainment. The 400
mm collecting plates are provided with hooks to their top edge for
suspension. The hooks engage in the slots of the supporting angles. All
the collecting plates in a row are held in position by a shock bar at the
bottom. The shock bars are spaced by guides.

Signatures
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Station: NTPC- Simhadri

BHEL Ref No.PS-DC-186-500-0043

NTPC Ref no SIM/1/TS/1/ 43

Sheet

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Plant area: BOILER

PROCEDURE FOR COMMISSIONING OF ESP
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STATUS

1.2.5

Emitting electrode: The most essential port of precipitator is supported

by four insulators. The frames are welded to form a rigid box like
structure for holding the emitting electrodes are located centrally
between collecting electrodes curtains. The emiting electrodes are hept
taut between the frames.

1.2.6

Rapping system: Rapping systems are provided for collecting and

emitting electrodes. These rappers are driven by geared motors. The
rapping system employs tumbling hammers which are mounted on a
horizontal shaft. As the shaft rotates slowly the hammers tumble on top
the shock bar/shock beam which tr5ansmits the blow to the electrodes.
The rapping shaft of emitting electrode of electrically isolated from the
geared motor drive by a shaft insulator. The space around the shaft
insulator is continuously heated to avoid condensation.

1.2.7

Insulator housing : The support insulators, supporting the emitting

electrode system are housed in insulator housings. The HV dc
connection is taken through a bushing insulator mounted on the
insulator mounted on the insulator housing wall.
Each support insulator is provided with one electrical heating element
controlled by thermostat. Figure 16.

1.3

ELECTRICAL SYSTEM

1.3.1

High voltage transformer rectifier (HVR) with electronic controller

(EC) : The transformer rectifier supplies the power for particulate
charging and collection. The basic function of EC is to feed the
precipitator with maximum power input under constant current
regulation. Whenever there is a flash between emitting and collecting
electrodes, the EC will sense the flash over and quickly react by
bringing the input voltage to zero an blocking it for a specific period.

Signatures
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BHEL

Station: NTPC- Simhadri

BHEL Ref No.PS-DC-186-500-0043

NTPC Ref no SIM/1/TS/1/ 43

Sheet

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Plant area: BOILER

PROCEDURE FOR COMMISSIONING OF ESP
SL.NO

STATUS
After the ionized gases are cleared and the dielectric strength restored,
the controller will quickly restore the power to a preset value and raise
it to the original non sparking level. The EC ensures adequate power
input to the precipitator while reckoning the electrical disturbances
within the precipitator. Regulated ac power from EC is fed to the
primary of the transformer precipitator, which is stepped up and
rectified to give a full wave power output. The transformer-rectifier is
mounted on roof of the precipitator which the EC is located in an air
conditioned control room.

1.3.2

Auxiliary control panel(ACP)

This is an LTMCC of modular construction with individual modules for
supplying power to the following equipment.
-Hopper heaters for each field
-Support insulator heaters
-Shaft insulator heaters
-Collecting electrode rapping for each field.
-emitting electrode rapping motor for each field.
-Opaque monitor
Safety interlock: A interlock system is incorporated to prevent
accidental contact with live parts of the precipitator and to enable
energisation only when the EP is boxed up.

1.3.3

Disconnecting switch: each field is provided with one disconnecting

switch for isolation of emitting system from the associated transformer.
In the ON position the emitting system is connected to transformer and
in OFF position the emitting system is grounded. Figure 18.

1.4

The specifications of ESP: Refer O & M Format No. 11

Sheets 01 to 06.

1.5

Refer to O & M Manual for schematic diagram of ESP.

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BHEL

Station: NTPC- Simhadri

BHEL Ref No.PS-DC-186-500-0043

NTPC Ref no SIM/1/TS/1/ 43

Sheet

5 of 19

Plant area: BOILER

PROCEDURE FOR COMMISSIONING OF ESP
SL.NO
2.0

STATUS
OBJECTIVE :
To commission ESP and make it available for Unit operation.

3.0

PROPOSAL :
ESP will be commissioned through the following proposals

3.1

Completion of Mechanical & Electrical checks.

3.2

Charging field and Air load test.

4.0

SERVICE REQUIRED:

4.1

Adequate lightening to be provided inside ESP for internal checks.

4.2

Availability of L.T. Power Supply

4.3

Availability of sealing arrangement at ESP Hopper bottom.

4.4

Availability of adequate communication facility at test area.

4.5

Availability of 3 Nos of hand torch (Battery operated)

4.6

Availability of manpower to check various parts of ESPs. (Both

Mechanical & Electrical)

4.7

Availability of oil filtering machine

4.8

Availability of 2.5/5KV motorized & 500V hand megger / Multimetor /

3 phase variac (15A)

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Station: NTPC- Simhadri

BHEL Ref No.PS-DC-186-500-0043

NTPC Ref no SIM/1/TS/1/ 43

Sheet

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Plant area: BOILER

PROCEDURE FOR COMMISSIONING OF ESP
SL.NO

STATUS

5.0

SAFETY PRECAUTIONS:

5.1

Ensure the availability of first aid kit in the ESP room

5.2

Ensure the availability of safety helmets for concerned personnel

5.3

Always ensure before entering any field the connected HV/LT supply is
isolated proper earthing of emitting electrode is done.

5.4

Never attempt to carry out

commissioning simultaneously

5.5

Ensure line clearance from the concerned boiler staff before entering
ESP.

5.6

The agencies working in ESP area are informed about ESP charging
activity.

5.7

ESP door interlock system is fully available and the master key should
be with designated person in the test team.

6.0

EMERGENCY PROCEDURE:

6.1

Keep a person always outside the field to extend necessary help in case
of Emergency during internal checking of ESP fields.

6.2

The test should be aware of the procedure adopted in testing schedule of

ESP.

6.3

The test team should be aware of steps to be taken in case of damage to

equipment / injury to personnel.

Mechanical

checking/Electrical

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BHEL

Station: NTPC- Simhadri

BHEL Ref No.PS-DC-186-500-0043

NTPC Ref no SIM/1/TS/1/ 43

Sheet

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Plant area: BOILER

PROCEDURE FOR COMMISSIONING OF ESP
SL.NO

STATUS

7.0

STATE OF THE PLANT:

7.1

The mechanical erection of all system have been completed During

mechanical checking of ESP internals, the connected ESP should have
been isolated electrically and proper earthing is done. Should get
clearance from boiler operation people to go inside ESP and check.

7.2

All Electrical system have been erected and electrical clearance

available for testing and commissioning.

7.3

L.T switch board, EC, ACP and disconnecting switches are off and fuses
are removed

7.4

All electrical equipment are earthed

7.5

Transformers negative bushings and emitting system frame work,

inspection doors and covers of insulator housings are earthed through
discharge rods.

7.6

Interlock sequence strictly adhered to

7.7

All safety aspects as given in safety instructions are taken care off.
(Refer O & M)

7.8

Debris and foreign materials such as welding electrode bits, temporary

supports etc are removed.

7.9

No hole in the wall, roofs and hopper plates are left open.

7.10

EP control room is air conditioned/ventilated.

7.11

Ash handling system is ready.

Signatures
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BHEL

Station: NTPC- Simhadri

BHEL Ref No.PS-DC-186-500-0043

NTPC Ref no SIM/1/TS/1/ 43

Sheet

8 of 19

Plant area: BOILER

PROCEDURE FOR COMMISSIONING OF ESP
SL.NO
7.12

STATUS
Ensure the following Critial dimensions / checks, (Machanical)
completed.
(To be verified through Erection log sheets)
-

Ensure the gap between Gas distribution screen and bottom of in let
funnel of ESP is 100+10 mm
Ensure Gas entry front casing wall and emitting electrode shock bar
is 350+10 mm
Ensure the distance between roof beam and emitting frame top is
195+5 mm minimum
Ensure support insulator bottom tip to emitting electrode frame top
is maintained as per drawing
Ensure the central line of collecting rapping drive shaft centre to
shock bar centre 310+5mm. If not available maintain it with proper
shims.
Emitting electrode support screen tube edge to emitting frame top
edge distance is maintained as per drawing.
Distance between centre of emitting system suspension point to first
hook with collecting electrode frames maintained as per drawing.
Emitting frames to collecting electrode distance maintained as per
drawing
Deflection plate to Emitting electrode suspension screen tube
dimension is maintained as per drawing
Confirm the suspension rod is centrally located with respect to
support insulator.
Confirm the shock pad and tumbling hammer face are in the same
vertical plane. If necessary confirm the same with chalk test by
running the collecting rapping of each field.
Set rings are in position.
Clearance between shock bar edge to shock bar guide is (40mm)
and shock bars are moving freely.

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BHEL

Station: NTPC- Simhadri

BHEL Ref No.PS-DC-186-500-0043

NTPC Ref no SIM/1/TS/1/ 43

Sheet

9 of 19

Plant area: BOILER

PROCEDURE FOR COMMISSIONING OF ESP
SL.NO

STATUS
-

7.13

Ensure shock bar guides and link rods are aligned properly.
Clearance between collecting electrode and hopper deflection plate
in the vertical plane as per drawing.
Straightness of shock bar and guide to be ensured.
The distance between emitting electrode and collecting electrode is
as per drawing.
The pitch distance of emitting electrode as per drawing.
Randomly check the spring back of emitting electrode
Verticality of all collecting electrode at all level to be ensured,
otherwise to be corrected.
Ensure deflection plates and throttling plates are arrested by
welding
Distribution screen manhole doors are locked in position.

RAPPING SYSTEM
-

Confirm collecting rapping gearedmotor, clutch and coupling

alignment
A slight axial play of the rapper shaft is maintained.
With rapping shaft. Mark the direction of rotation of the rapping
shaft outside. Even a short running of shaft in reverse direction will
extensively damage the shock bars.
Check the pin wheel arrangement for proper erection and confirm
proper transmission of torque from rapping shaft. A minimum axial
play of 5 mm on either side of shaft insulator is maintained.
Correctly mark the direction of rotation over the geared motor.
Confirm correct style of scavenging screws are installed
concentrically around the shaft insulators.

Signatures
NTPC

BHEL

Station: NTPC- Simhadri

BHEL Ref No.PS-DC-186-500-0043

NTPC Ref no SIM/1/TS/1/ 43

Sheet 10 of 19

Plant area: BOILER

PROCEDURE FOR COMMISSIONING OF ESP
SL.NO

STATUS
-

7.14

Check the collecting rapping shaft and emitting electrode rapping

shaft-sealing arrangement as per drawing.
Confirm proper alignment of plain bearing and set rings and proper
seating of rapping shaft in the bearing.
Drain the old oil from the gear box and fill new oil into the gear box
as per lubrication recommended upto the correct level marked..
Confirm all drive motors bearings are greased
Check all motor bolts are properly tightened after alignment.
All the drive bolts and nuts are to be tack welded once
commissioning check is completed.

INSPECTION DOOR ON CASING AND HOPPERS

-

Ensure that doors are swinging freely and latches are engaging
properly with doors, Gaskets are air tight
Earthing cable is connected properly.
Interlocks and keys are matching properly

8.0

METHOD:

8.1

Auxiliary Control Panel (Electrical)

- Confirm the ACP erected as per drawing
- Confirm the availability input power supply and rated voltage etc.
- Check the input and output bus bars for proper tightening of all
connected fasteners including earthing.
- Check in each module the followings items wherever supplied for
physical availability and conditions.
Ammeter, Voltmeter and their selector switches, Fuse units with correct
rated fuses, Isolating switch, Indicator lamps with series resistor,
Current trans former, hopper heater, Shaft and support insulator heaters
availability at their locations with thermostats, contactors, control
supply transformers, thermal overload correct setting as per the rating of
the equipment, Ash level indicator sensors availability in their respective
hoppers, Start /stop Local push button stations for proper wiring
( confirm water proof arrangement).

Signatures
NTPC

BHEL

Station: NTPC- Simhadri

BHEL Ref No.PS-DC-186-500-0043

NTPC Ref no SIM/1/TS/1/ 43

Sheet 11 of 19

Plant area: BOILER

PROCEDURE FOR COMMISSIONING OF ESP
SL.NO

STATUS
- Confirm the cable size, proper cable glanding, earthing of shielded
input cables and output cables as per drawing
- Megger IR value of the input cables to the panel from incomer-A to
panel
bus section -A and the input cables to the panel from
incomer-B to panel bus section-B independently with respect to earth
by keeping open their respective ACBs open.
- Megger the panel power supply control supply buses, heater control
supply and 240 bus bar.
- Confirm the availability of DC 220V and match both the sources for
+ and . Close one of the DC-IS switches and establish control DC
power supply bus for energizing ACBs. Similarly isolate the first DCIS and energies the second source and establish 220 V DC control
supply bus to ACBs.
- Confirm the two source of power supply from LTMSB, three phases
are having the same voltage with respect to earth. Measure phase to
phase voltage also and confirm equal. Check and correct phase
sequence of both source.
- Check the relay setting of ACB1, ACB2 and ACB3as per
recommendations.
- Charge the ACP bus section-A by ACB1 closing.
- Confirm the voltage reading in all the three phases are reading
correctly. Check the 240V bus voltage with respect to Neutral bus
bar, Similarly check 110V bus voltage with respect to Neutral bus bar
for both motor control supply and heater control supply. Similarly
Change the TPDT SW of control transformer and repeat checking all
bus bar voltages as earlier
- Repeat the same for ACP BUS SECTION-B as 8.49 to 8.50
- The interconnecting ACB3 has to be kept opened, match the phase
sequence of the both the panel buses.
- Open ACB2, CloseACB3 check the output bus voltage of entire
ACP.
- Open out ACB1, ACB3 opens out. Close ACB2, close ACB3
reconfirm the output bus voltages.

Signatures
NTPC

BHEL

Station: NTPC- Simhadri

BHEL Ref No.PS-DC-186-500-0043

NTPC Ref no SIM/1/TS/1/ 43

Sheet 12 of 19

Plant area: BOILER

PROCEDURE FOR COMMISSIONING OF ESP
SL.NO
8.2

STATUS
Collecting and emitting Rapping System Commissioning :
Geared motors :
-

8.3

In case of emitting electrode rapping system confirm that heating

elements are properly fixed.
Confirm glands are properly placed
Insulators are healthy, clean and rigid without crack.
Confirm the mechanical clearance for each rapping system and
decouple the motor.
Confirm the tightness of motor terminated cables, proper earthing,
proper dressing of cables.
Megger the motor and record the IR value. Measure the coil
resistance and record. Confirm IR value is atleast 1Mohm.
Otherwise heat the motor and till the IR value is satisfactory.
Confirm the local push button station control supply terminal are
properly done.
Energise the concerned module and locally bump and confirm
direction.
If the direction is reverse, correct the direction.
Couple and take trial run as per duty cycle of the motor to study the
proper hammering. If the hammering is in the centre of shock pad
in case of collecting rapping system for all the hammers and the
hammer in the centr of shock beam in case of emitting rapping, stop
the rapping motors.
Clear for tack welding of all bolt and nuts of hammers etc.
Commission all the rapping motors of all fields as above.

Heating Elements :
-

Ensure the IR value is more than 2M ohm

Continuity is ascertained
Cables are terminated properly with crimped lugs and glands and
terminal box cover is watertight.

Signatures
NTPC

BHEL

Station: NTPC- Simhadri

BHEL Ref No.PS-DC-186-500-0043

NTPC Ref no SIM/1/TS/1/ 43

Sheet 13 of 19

Plant area: BOILER

PROCEDURE FOR COMMISSIONING OF ESP
SL.NO

STATUS
-

8.4

Cable Armour and earth points are terminated to earth.

Set the thermostat for hopper heaters at 120 deg C and 140 der C
for support insulators. Verify the proper cable termination and
continuity of thermostats. Swithch on the module and check the
performance.

Disconnecting switches
-

8.5

Ensure Insulators are healthy, clean and rigid

HV bus terminal and earthe connections inside are tight.
Operation of moving blades with HV and HV and earth contact is
smooth and proper.
Copper cable between moving arm and insulator head is properly
connected. Each disconnecting switch is provided with a danger
plate and two external earth connections to earth mat.
Doors are closed tightly
Interlocks provided at doors handles are working properly.

INSULATOR HOUSING
-

8.6

Insulators are clean, healthy and rigid

Copper tubes are straight and not loose
Heating elements are properly fixed
Earthing is proper
Screw legs and nuts for placement of alignment jigs are welded
Doors are closed tightly
Interlocks are working properly
Each insulator housing is provided with a danger plate and two
external earth connection to earth grid.

HIGH VOLTAGE BUS DUCTS

-

Ensure flange ioints are provided with gasket and earthing cables.
Copper tubes are straight and tightly connected

Signatures
NTPC

BHEL

Station: NTPC- Simhadri

BHEL Ref No.PS-DC-186-500-0043

NTPC Ref no SIM/1/TS/1/ 43

Sheet 14 of 19

Plant area: BOILER

PROCEDURE FOR COMMISSIONING OF ESP
SL.NO

STATUS

8.7

ELECTRONIC CONTROL(EC) WITH HVR SYSTEM : (Refer

INSTRUCTION MANUAL FOR SCR CONTROLLED HVDC
Power supply 70KV dc Peak, 1200mA.DC Avg /BHEL/JHANSI and
BAPCON MANUAL)

8.8

Visual Check : Before energizing the control cubicle a visual check is

to be made. Check all components are in proper position and all the
connection as per wiring drawings. If necessary restore the connections

8.9

Electrical Checks : Refer power and control schematic drawing.

Disconnect the connector of Integrated controller short wires :
Group A: Short primary and secondary of aux. transformer T1, T2, T3.
Earthing of one end of winding of above transformer to be removed.
Group :B 103, 104 and Line contact of 52 CONTACTOR.
Measure the insulation resistance with 500 Volt megger between group
A and Earth E, B & E and between A & B IT SHOULD BE AS
FOLLOWS
A to E > 2Mohm
A to B > 30Mohm
B to E > 30Mohm
a) Normalise the shorting after insulation check and connect
microprocessor controller .
b) Connect a load resistor of approximately 4Amps, 2000 watts, 500
Volt at C & D of the panel.
c) Connect supply 415 V AC, 50Hz across terminals A & B of the
panel
d) Close the isolator ( 29) and check the indication for mains on ,
display and flickering of processor health indicating LED of
Controller.

Signatures
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BHEL

Station: NTPC- Simhadri

BHEL Ref No.PS-DC-186-500-0043

NTPC Ref no SIM/1/TS/1/ 43

Sheet 15 of 19

Plant area: BOILER

PR CEDURE FOR COMMISSIONING OF ESP
SL.NO

STATUS
e)

Check supply 24V AC at terminal 1 & 5 of TB2 with respect to

ground.
f) Check 18V AC at across pin 1 & 2 of firing circuit.
g) Keep controller in local mode.
h) Press HT on/off of push button of controller AND see that a voltage
of the order of 400 volts appears in meter across load. Please note
the output voltage cannot be controlled by current limit
potentiometer with factory set parameters. For details close loop
test manual of microprocessor controller. may be referred.
i) Check the annunciation by shorting terminal s 2, 3, 4, 5 of TB1 with
respect to earth i.e HVR interconnection. Operate thermal overload
relay and check the annunciation and tripping of contactor. Under
voltage alarm shall be annunciated of 40 sec time making HT on
provided fault exists.
j) Contactor can also be made OFF by pressing HT on/off push button
on controller once more.
With this controller is ready for commissioning
HVR SYSTEM : 70 KV DC Peak, 1200 mA.DC Avg. with Silicone
oil filled.Input AC current to HVR 241 Amps. Input primary voltage is
415 volt
DRYING OUT CHECKS:
Oil test : Oil samples from top/bottom of tank is taken BDV value to
checked at lab. The BDV should be atleast 25kv. If the BDV is less than
25 BDV, the oil is filterd through a filter machine till the BDV is
achieved.
Buchholtz relay : Check the the relay for visual damage and correct
acting of relays and their mercury switches.

Signatures
NTPC

BHEL

Station: NTPC- Simhadri

BHEL Ref No.PS-DC-186-500-0043

NTPC Ref no SIM/1/TS/1/ 43

Sheet 16 of 19

Plant area: BOILER

PROCEDURE FOR COMMISSIONING OF ESP
SL.NO

STATUS
Oil temperature indicator: Check the indicator for visual damage, for
proper wiring for alarm and trip.
Completion of job: Check the oil level and top it upto requirement with
dry oil. Check the complete wiring for various alarm/trip contacts tank
and HIV positive terminal is completed.
IR value of transformer windings : 8.98 Measure the IR value
which should be typical to the one given H-E = 200Mohm; L-E =
200Mohm: H-L = 200Mohm.
Open circuit Test :
a). Magnetising Curent Test: Prepare a circuit diagram as shown in
the instruction manual of HVR in page C-12. In this test, the primary of
HVR is fed from a two phase variac 500V/10A, and the magnetizing
current drawn by HVR is measured. This may be compared with the test
result of HVR.
b).Output voltage measurement : The measurement of HV open
circuit output voltage should be done in conjunction with EC and this
should be of the order of rated output DC KV. ( 70KV Peak).
Field IR VALUE measurement: Keep the HVR FIELD ISOLATOR
SWITCH in middle position measure the IR of the field and confirm no
shorting.
Commissioning the field.
Connect the transformer rectifier as per drawing
a)
b)

Close the field isolator on top of the EP.

Ensure Microprocessor controller is in local mode.

Signatures
NTPC

BHEL

Station: NTPC- Simhadri

BHEL Ref No.PS-DC-186-500-0043

NTPC Ref no SIM/1/TS/1/ 43

Sheet 17 of 19

Plant area: BOILER

PROCEDURE FOR COMMISSIONING OF ESP
SL.NO

STATUS
c)

Keep current limiting potentiometer of controller in minimum

position
d) Close the isolator(29)
e) Check the indications and Microprocessor controller as given inn
the BAPCON manual.
Check the various settings of Microprocessor Controller parameters
by pressing increment or decrement push-button. It should be
identical to factory set value ( refer Manual of Microprocessor
Controller ).
f) Keep the current limit potentiometer to 50% position, this could be
seen in microprocessor controller display parameter (1).
g) Press HT on/off push-button of controller so as to close contactor
(52). The output voltage and current shall start building up at time
over ride initially then follow T: setting. Increase the current limit
to 100% for rated current. Check voltage across shunt, it should be
approximately equal to IratedX Rshunt Volts Dc. The voltage at pin
F of MCRP card should be approximately 1 volt DC at full load
otherwise adjust MCP2 potentiometer.
Follow the safety rules and regulation while charging EC-HVR
a.

On appearance of spark across electrode, the spark counter shall

register one count and output shall be blocked for a certain time.
Then current will reach value as per S control setting and again
build up at T setting rate. The spark sensitivity is factory set.
However if required can be set with SS potentiometer.

AIR LOAD TEST : Air load test is an important commissioning

activity. This gives the diagnosis of the following.

Proper erection and alignment of EP internals

Presence of any left out debris/hanging pieces which may limit the
voltage or short the electrodes.
Healthiness of insulators
Healthiness of transformers and electronic controllers.

Signatures
NTPC

BHEL

Station: NTPC- Simhadri

BHEL Ref No.PS-DC-186-500-0043

NTPC Ref no SIM/1/TS/1/ 43

Plant area: BOILER

PROCEDURE FOR COMMISSIONING OF ESP

Sheet 18 of 19

SL.NO

STATUS
PREPARATIONS :

This air load test has to be carried out at a time with one ESP
consisting of eight fields.
Remove all temporary earth connection made with discharge rods
Confirm that rapping system/EC-HVR system of all the fields
which are to be air load tested are commissioned and ready for
operation.
If necessary for reconfirming the IR value of the field, meggering
may be carried out by between earthing and emitting electrode at
disconnecting switch by keeping open the moving blade in between
the two fixed contacts. Close the disconnecting switch after IR
value measurement.
Close all insulator housing, disconnecting switch and inspection
doors adopting interlock sequence and return the key to the
electronic controller.
Confirm from the concerned personnel that nobody having any
inspection work in the concerned ESP ducts and get clearance for
charging the ESP.

POCEDURE :
Make supply available to ACPs and Ecs.
Switch on all rapping motors on continuous mode.
Switch on EC and slowly raise the current. Note the meter reading
for each interval of 50 mA. Raise upto rated current. Look for
flashover if any and record.
The rapping motors are to be changed to intermittent rapping mode
after taking voltage & current readings.
Keep all the fields energised for a period of 8 hours.
Log air load readings at every one hour interval.
Switch off the ECs, ACPS AND L.T. Board.

Signatures
NTPC

Station: NTPC- Simhadri

Plant area: BOILER

BHEL

BHEL Ref No.PS-DC-186-500-0043

NTPC Ref no SIM/1/TS/1/ 43

Sheet 19 of 19

PROCEDURE FOR COMMISSIONING OF ESP

SL.NO
9.0

STATUS
COMPLETION OF ESP COMMISSIONING:
ESP Commissioning completed by completing the proposals given in
Section 3.0.

Signatures
NTPC

BHEL

PROCEDURE FOR COMMISSIONING OF ESP