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Enviro Division
Installation &Commissioning Manual
Improving Your BusinessIs Our Business
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COMPANY PROFILE
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’.
Enviro Division
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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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Contents
Electrostatic Precipitator
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Contents
Sr. No. Chapter Page No.
1. INTRODUCTION 01
2. GUIDELINES ON HEALTH AND SAFETY MEASURES 02
3. PRINCIPLE OF ESP OPERATION 05
4. FACILITIES FOR THERMAX SITE SUPERVISOR 06
5. GUIDELINES ON STORAGE FACILITIES & STORAGE INSTRUCTIONS 07
6. GUIDELINES ON RECEIVING & STACKING OF MATERIAL 09
7. STANDARD ESP ACTIVITY CHART WITH MAIN & PARALLEL ACTIVITIES 12
8. GUIDELINES ON ESP PRE-ERACTION ACTIVITIES 19
9. GUIDELINES ON ESP MECHANICAL ERECTION ACTIVITIES 37
10. ELECTRICAL ACTIVITIES 138
11. ESP PRE-COMMISSIONING CHECKLISTS 152
12. PRE-COMMISSIONING ACTIVITIES 157
13. COMMISSIONING ACTIVITIES 168
14. PRECAUTIONS FOR SMOOTH & TROUBLE FREE FUNCTIONING OF ESP 174
15. SAFETY RISK ASSESSMENT FOR ESP ACTIVITIES 179
16. STACK SAMPLING PROCEDURE 186
17. LIST OF TWO YEARS OPERATING SPARES 190
ELECTROSTATIC PRECIPITATORInstallation & Commissioning Manual
Introduction
Chapter 1
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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:
1. Assist in understanding the construction features of THERMAX make ESP.
2. Guide the field staff to understand the working and importance of various parts and care to be taken while
handling the ESP parts.
3. Planning the schedule of ESP erection.
4. Help in achieving the best results of ESP in its long run.
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.
For any doubts or clarification, feel free to contact us at following address
M/s THERMAX LIMITED
ENVIRO DIVISION
PMT COMPLEX,
BEHIND PCMC BUILDING,
MUMBAI PUNE ROAD,
PIMPRI,
PUNE 411 018
EMAIL : [email protected]
Installation & Commissioning Department
ELECTROSTATIC PRECIPITATORInstallation & Commissioning Manual
Guidelines on Health & Safety Measures
Chapter 2
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Guidelines on Health & Safety Measures
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During erection activity of ESP, Customer / Erectors must take care of all health and safety measures, as per the rules
and regulations applicable in the local area where ESP installation and commissioning is to be done. For any
failure/s, due to negligence of safety and health issues, Thermax will not be responsible.
Following minimum health & safety measures are recommended.
1. First aid boxes must be kept at easily accessible places of the work site.
2. At least two trained persons in the first aid treatment must be present while the work is in progress at erection
and / or fabrication / assembly site.
3. Site contractor’s all workmen must be introduced to safety and health program, before commencing the
erection / fabrication / assembly activity.
4. Emergency telephone numbers like plant medical aid, fire station, plant security gate, nearest hospital must
be kept handy by contractor’s all supervisors. Also these telephone numbers are to be displayed prominently
in front of customer’s, Thermax’s and contractor’s site offices for ready reference to all workmen.
5. All plane equipment / machines like cranes, winch, lifting equipment, welding machines, gas cutting sets etc,
must be operated by only trained and authorised operators.
6. All personnel working at site must wear the basic PPEs like safety helmets, safety shoes. The other safety items
like safety belts, safety goggles, earplugs, welding screens, masks and gloves etc, should be used as and
when required.
7. Barricades and danger warning signs must be displayed at all locations to prohibit the entry of unauthorized
persons.
8. A considerable portion of the ESP alignment work is done in confined space. Hence precautions related to
working in confined space must be adhered.
9. The ESP erection takes place at high elevations. Hence special care must be taken while working at high
attitude. Lifeline, platform / handrails, barricades, temporary platforms / ladders must be made available
whenever required.
10. For welding the temporary ladder / steps on casing columns, use only plain mild steel rods. The tor steel rods
must not be used for this purpose, as welding of tor steel with mild steel is not safe.
11. While working at height, the workmen need to tie the safety belt (full body harness)at one fixed location. For
this purpose, always weld a proper lug on the top area of the item being lifted, at needed places, so that
workmen can tie his safety belt to such lugs when ever he goes on top.
12. All the lifting equipment e.g. crane, winch, other material handling equipment like chain blocks, hydra, fork
lift, silings, wire ropes, D-shackles, rope pulleys etc. must be tested for their safe work loads. Such test
certificates from an authorised agency must be submitted while bringing the equipment at site. All safety
alarm and controls of material handling equipment should be available in working condition.
13. Whenever the erection work at height is going on, no man movements are allowed below such area. Safe
working barricades should be provided in such area.
ELECTROSTATIC PRECIPITATORInstallation & 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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ELECTROSTATIC PRECIPITATORInstallation & Commissioning Manual
Principle of ESPOperation
Chapter 3
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Installation & Commissioning Manual
Principle of ESP Operation
ELECTROSTATIC PRECIPITATOR
Electrostatic Precipitator [ESP] is used to separate and collect dry dust from process gases.
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.
Chapter 4
Facilities
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Facilities for THERMAX Site Supervisor
A lockable, well-ventilated office of minimum 10-sq.m area per person should be provided for Thermax Site
Supervisor.
The office equipment should be provided with following:
+Desk
+Chairs
+Cupboard for documents.
+Electrical Connection with sufficient illumination
+Washing facilities.
+Sanitary facilities
+Communication facilities (Local / STD telephone)
The above facilities are considered adequate for a single supervisor. If necessary, such facilities should be made
available for additional engineers / supervisors.
Installation & Commissioning Manual ELECTROSTATIC PRECIPITATOR
Chapter 5
Guidelines on Storage Facilities
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Guidelines on Storage Facilities & Storage Instructions
The typical storage area required for storing the ESP material should be:
+Approx. 1500 sq. meter of fenced lockable open yard.
+Approx. 500 sq. meter of covered lockable area in sheds.
The storage area should be located near to the unit to be installed.
The storage area should be practicable for driving with mobile cranes and other transport vehicles.
The above requirements are worked out considering sequential supply and erection of items. If the erection activities
are delayed, bigger space (both open & shed) would be required.
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.
Installation & Commissioning Manual ELECTROSTATIC PRECIPITATOR
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.
ATTENTION: Non observance of the above instructions will absolve THERMAX from every liability
concerning erection problems.
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.
8
Installation & Commissioning ManualELECTROSTATIC PRECIPITATOR
Chapter 6
Guidelines on Receiving &Stacking of Material
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Guidelines on Receiving & Stacking of Material
The instructions given below are to be used as a guideline for receiving & storing the materials at site, when it is
received at site.
Receiving the Material:
a. Prior to reaching the ESP material at site, the storage area is to be identified & barricaded with a gate under
lock & key. The area should be leveled without any potholes & ridges. In the storage area, the trailer / truck
should have easy approach. Also sufficient place for movement of crane / Hydra should be available during
unloading & shifting the material to erection site.
b. As soon as the material (loose / package / boxes) arrived at site, it should be checked for any transit damages.
In case of major transit damage to the material, all the details pertaining to the consignment is to be noted
along with the identity of the driver. The nature of the damage to be recorded along with the acknowledgment
from the transporter driver / representative. If possible, the photographs shall be taken in all possible angles.
The scope of transit Insurance is to be checked and accordingly intimation to M/s THERMAX LTD. (ENVIRO
DIVISION) – Pune, should be given. In the damage report, the details like L.R. No., Truck No., Transporter’s
Name, Delivery Challan and Description of the materials damaged must be mentioned. While unloading,
the material should be reconciled with Thermax’s and / or its vendor’s respective delivery challan / packing
slip / loading report.
c. While unloading, all loose materials should be counted and ensured. Any shortages or damages of the
material should be recorded on the L.R. and should be acknowledged by the truck driver. All packed cases
should be opened and checked within 7 days of receipt of material at site and any discrepancy should be
informed to the concerned project engineer at Pune immediately. All such packed cases, which were opened
for material inspection, should be re-packed properly to avoid any theft / loss of the material.
d. Record Keeping: All delivery challans / packing slips / loading reports should be filed serially. Once the
received materials are unloaded and verified with packing slips / delivery challans / loading reports, these
materials should be checked with respect to respective BoM (Bill of Material). Then remarks shall be made on
BoM i.e. on the right hand side of BoM showing the D.C. no. and no. of pieces received.
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.
Installation & Commissioning Manual ELECTROSTATIC PRECIPITATOR
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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.
Installation & Commissioning ManualELECTROSTATIC PRECIPITATOR
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Sketch No. 001 - Handling Instructions
Installation & Commissioning Manual ELECTROSTATIC PRECIPITATOR
Chapter 7
Standard ESP ActivityChart
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Standard ESP Activity Chart with Main & Parallel Activities
Following table gives the brief idea on the main and parallel activities of ESP erection.
Installation & Commissioning Manual ELECTROSTATIC PRECIPITATOR
Parallel Activity Main Activity Parallel Activity
1. Foundation Checking
2.1 Ground Assembly of Casing Panels with columns
2. Support Structure Erection and Alignment
2.2 Ground Assembly of Inlet Nozzle with GD Screen
3.1 Ground Assembly of Outlet Nozzle with GD screen
3. ESP Bearing installation and Alignment
3.2 Ground Assembly of Hopper with baffle plates
4. ESP casing Erection, Alignment and Welding
5.1 Erection, Alignment and welding of staircase and platform with railings
5. Erection and alignment of collecting plate floating channel arrangement
6. Assembly of collecting plate panels
7.1 Erection, Alignment and Welding of Inlet Nozzle with GD Screen
7. Erection of collecting plate panels ( by crane / by winch)
7.2 Erection, Alignment and Welding of Outlet Nozzle with GD Screen
8. Alignment of collecting panels
9. Positioning of top HV frame ( by crane / by winch)
9.2 of inner roof
Erection, Fit-up and welding
10.1 Welding of ESP penthouse
Erection, Alignment and 10. Fixing of rigitrodes to top HV frame
11.2 structure
Erection of Monorail with its 11.1 Erection of hopper and its allied parts. (Fix regitrode guide frame temporary support inside the hopper.)
11.Installation and Alignment of support insulator and its allied parts
12.1 Fixing of electrical items. 12. Loading of support insulators
13.1 Fixing of the cable trays on ESP, for all cables (like power cables, control cables, Feedback Cables etc.)
13.Checking the straightness of regitrodes in free hanging condition and its straightening if required
13.2 Erection & Alignment of collecting plate Rapping System
14.1 Cable laying 14. Fixing the guide frame to regitrodes
14.2 Erection & Alignment of Regitrode Rapping System
15.1 Cable Termination 15. Alignment of regitrodes w.r.t. collecting plates
15.2 Erection & Alignment of Inlet GD Rapping System
16.1 Cable Dressing 16. Air leak test 16.2 Thermal Insulation Application (After Air Leak Test)
17. Fixing of mechanical interlock system, Sign and brackets
12.2 Erection of TR set base frame and TR set
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
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
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Activity No.Approx. Day of TL
Engineer
1
2
3
4
5
6
7
8
2
2
3
5
3
9
10
11
12
13
14
15
16
17
2
2
3
4
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6
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Foundatio
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Dim
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Vis
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Vis
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10
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10
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10
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10
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As
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Vis
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Measu
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10
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10
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10
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10
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10
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10
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10
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As
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3m
m w
.r.t.
fixed
bearing c
olu
mn)
As
per
Dra
win
gA
s per
dra
win
g w
ithin
+
/- 5
mm
tole
rance
Vertic
alit
y1m
m/m
tr o
r m
ax.
10
mm
whic
h
eve
r is
min
.A
s per
speci
ficatio
n
Struct
ura
l Bearing
3.
Identif
icatio
n
Orienta
tion
Conditi
on
Alig
nm
ent
Sprit Le
vel
Wate
r Le
vel of
bearing top
Vis
ual
Vis
ual
Vis
ual
Measu
rem
ent
Vis
ual
Vis
ual
10
0%
10
0%
10
0%
10
0%
10
0%
10
0%
As
per
Dra
win
gA
s per
Dra
win
gG
ood C
onditi
on
As
per
dra
win
gC
orr
ect
Spirit
Leve
lW
ate
r le
vel w
ithin
+/-
2m
m w
.r.t.
fixed b
earing
Orienta
tion
Dim
ensi
on
Vertic
alit
yFi
t up
Prim
er
Touch
Vis
ual
Plu
mb
Measu
rem
ent
Sr. N
oD
esc
ription
Chara
cteri
stic
s to
be
check
ed
Meth
od o
f ch
eck
Ext
ent
of
check
Acc
epta
nce
sta
ndard
Therm
ax
Cust
om
er
Ere
ctio
nA
gency
Meth
od
of
Reco
rd
Proto
col
Proto
col
Proto
col
Proto
col
Proto
col
Proto
col
Proto
col
Proto
col
Proto
col
4C
asi
ng,
Inle
t &
O
utle
t N
ozz
le,
Hopper, R
oof
Panel,
Penth
ouse
Identif
icatio
n
Conditi
on &
Health
iness
Fit up (dia
gonals
&
dim
ensi
ons)
Prim
er
touch
Vis
ual
Vis
ual
Measu
rem
ent
Vis
ual
10
0%
10
0%
10
0%
10
0%
As
per
dra
win
gG
ood C
onditi
on
As
per
dra
win
g
As
per
speci
ficatio
n
Proto
col
P P P P
W R W R
W W W W
P P P P P P P
W W W W W W W
P P P P P P
W W W W W W
W W W W W WW W W W W W W
P P P P
W W W W
W W W W
14
Installation & Commissioning Manual ELECTROSTATIC PRECIPITATOR
Colle
ctin
g P
late
Sy
stem
Id
entif
icatio
n
Conditi
on
Stra
ightn
ess
at pla
te
end
Fit up
Alig
nm
ent
Vis
ual
Vis
ual
Use
st
raig
htn
ess
jigVis
ual
Vertic
alit
y Sp
aci
ng
10
0%
10
0%
10
0%
10
0%
Random
Random
As
per
Dra
win
gG
ood C
onditi
on
Stra
ight w
ithin
+/-
3
mm
As
per
Dra
win
gW
ithin
+/-
4m
mg
As
per
Dra
win
g
P P P P P P
R W W W W W
IR IR IR
Reg
itrode
Syst
emId
entif
icatio
n
Conditi
on &
H
ealth
ines
sSt
raig
htn
ess
Alig
nm
ent
Vis
ual
Vis
ual
Stra
ight in
hangin
g
conditi
on
Vis
ual
Vertic
alit
y Sp
aci
ng
10
0%
10
0%
10
0%
10
0%
10
0%
Random
As
per
Dra
win
gG
ood C
onditi
on &
St
raig
ht Pi
ns
Stra
ight w
ithin
+/-
5
mm
As
per
Dra
win
gW
ithin
+/-
4m
mg
As
per
Dra
win
gIR IR
P P P P P P
R W W W W W
5. 6
Colle
ctin
g a
nd
Rig
itrode
Rapper
s
Iden
tific
atio
n
Conditi
on
Hea
lthin
ess
Fit up
Alig
nm
ent/
vertic
alit
y
Vis
ual
Vis
ual
Vis
ual
Vis
ual
Mea
sure
men
t
10
0%
10
0%
10
0%
10
0%
10
0%
As
per
Dra
win
gG
ood C
onditi
on
Good C
onditi
on
As
per
Dra
win
gA
s per
Dra
win
g
P P P P P
W W W W W
IR IR IR IR
8.
Caro
na G
ap
Insp
ectio
nM
easu
rem
ent
Mea
sure
men
t1
00
%A
s per
guid
elin
e in
manual
Proto
col
PW
7.
W
Support &
Sh
aft Insu
lato
rsId
entif
icatio
n
Conditi
on
Hea
lthin
ess
Fit up
Vis
ual
Vis
ual
Vis
ual
Vis
ual
10
0%
10
0%
10
0%
10
0%
As
per
Dra
win
gG
ood C
onditi
on
Good C
onditi
on
As
per
Dra
win
g
IR IR IR IR
P P P P
W W W W
9.
W W W W
Gas
Dis
trib
utio
n
Scre
en
Iden
tific
atio
n
Conditi
on
Hea
lthin
ess
Fit up
Alig
nm
ent/
vertic
alit
y
Vis
ual
Vis
ual
Vis
ual
Vis
ual
Mea
sure
men
t
10
0%
10
0%
10
0%
10
0%
10
0%
As
per
Dra
win
gG
ood C
onditi
on
Good C
onditi
on
As
per
Dra
win
gA
s per
Dra
win
g
IR IR IR
P P P P P
W W W W W
10
.W W W W W
Sr. N
oD
esc
ription
Chara
cteri
stic
s to
be
check
ed
Meth
od o
f ch
eck
Ext
ent
of
check
Acc
epta
nce
sta
ndard
Therm
ax
Cust
om
er
Ere
ctio
nA
gency
Meth
od
of
Reco
rd
W W W W W W W W W W WW W W W W W
15
Installation & Commissioning ManualELECTROSTATIC PRECIPITATOR
16
Installation & Commissioning Manual ELECTROSTATIC PRECIPITATOR
Exp
ansi
on
Join
ts &
H
opper
Slide
Gate
s (If
applicable
)
Identifica
tion
Conditio
n D
imensi
ons
Healthin
ess
Fit u
pA
lignm
ent
Vis
ual
Vis
ual
Measu
rem
ent
Vis
ual
Measu
rem
ent
10
0%
10
0%
10
0%
10
0%
10
0%
As
per
Dra
win
gA
s per
Dra
win
gA
s per
Dra
win
gA
s per
Dra
win
gA
s per
Dra
win
g
Therm
al
Insu
lation
Identification
Vis
ual
10
0%
As
per
Dra
win
g
P P P P P
W W W W W
PW
IR IR IR
Purg
e A
ir
syst
em
Id
entification
Conditio
nH
ealthin
ess
Fit u
pA
lignm
ent
Functional check
Vis
ual
Vis
ual
Vis
ual
Vis
ual
Measu
rem
ent
Vis
ual
10
0%
10
0%
10
0%
10
0%
10
0%
10
0%
As
per
Dra
win
gG
ood C
onditio
nG
ood C
onditio
nA
s per
Dra
win
gA
s per
Dra
win
gD
irection o
f ro
tation &
C
urr
ent dra
wn
IR IR IRPC
R
P P P P P P
W W W W W W
Leak T
est
ing
of ESP
Identification o
f W
eld
ing L
eakages
As
desc
ribed
belo
w1
00
%A
ir L
eak T
est
Pro
tocol
PW
Cable
layi
ng
/ Te
rmin
ation
and E
arthin
g
Identifica
tion
Cable
Layi
ng
Cable
Routing
Cable
Term
ination
Vis
ual
Vis
ual
Vis
ual
Term
inal poin
ts
10
0%
10
0%
10
0%
10
0%
As
per
cable
sch
edule
As
per
dra
win
gA
s per
dra
win
gA
s per
cable
sch
edule
P P P P
R R R R
11
.
14
.
12
.
13
.
15
.
Transf
orm
er
Rectifier
Set
Identifica
tion
Loca
tion
Ele
ctrica
l Te
sts
D
ie e
lect
ric
Strength
of Tr
ansf
orm
er
Oil
TR s
et M
egger
Test
s
Lam
p L
oad test
Short C
ircu
it T
est
Vis
ual
Vis
ual
BD
V T
est
er
By
megger
Usi
ng 1
00
w
lam
ps
in s
eries
By
connecting
TR -
ve b
ush
ing
to e
arth
10
0%
10
0%
10
0%
PC
R
PC
R
PC
R
PC
R
P P P P P P
W W R P P P
16
.
Sr. N
oD
esc
ription
Chara
cteri
stic
s to
be
check
ed
Meth
od o
f ch
eck
Ext
ent
of
check
Acc
epta
nce
sta
ndard
Therm
ax
Cust
om
er
Ere
ctio
nA
gency
Meth
od
of
Reco
rd
Should
be
more
than
50
KV w
ith 2
.5m
m g
ap
As
per
Pre
-co
mm
issi
onin
g R
eport
As
per
Drg
.A
s per
Drg
.
Lam
p s
hould
glo
w
stea
dily
with
out
flick
erin
gTo
rate
d v
alu
e of
prim
ary
& s
econdary
cu
rren
t
W W W W W WW W W W W W W W W W W W W P W W W
17
Installation & Commissioning ManualELECTROSTATIC PRECIPITATORD
esc
ription
Chara
cteri
stic
s to
be
check
ed
Meth
od o
f ch
eck
Ext
ent
of
check
Acc
epta
nce
sta
ndard
Ere
ctio
nA
gency
Meth
od
of
Reco
rd
Open
Circu
it Te
st IR T
est
Wirin
g c
hec
k and c
harg
ing
panel
10
0%
PCR
P P
Therm
ax
Cust
om
er
P P
W
Mec
hanic
al Key
Inte
rlock
Sy
stem
Iden
tific
atio
nLo
catio
nFu
nct
ional Te
st
Vis
ual
Vis
ual
Oper
atio
n
10
0%
10
0%
10
0%
As
per
Drg
.A
s per
Drg
.A
s per
Drg
.
P P PIR
17
W W P
W W W
PPC
R
Rapper
Control
Panel
IR T
est
Funct
ional ch
eck
By
Meg
ger
Ele
ctrica
l Te
sts
10
0%
10
0%
As
per
Pre
-co
mm
issi
onin
g R
eport
PCR
PCR
P P
Hopper
hea
ters
(if
applic
able
),
Insu
lato
r hea
ters
&
Hopper
lev
el
switc
hes
.
Iden
tific
atio
n
Conditi
on
Hea
lthin
ess
Fit up
Funct
ional ch
eck
Vis
ual
Vis
ual
Contin
uity
Tes
t
Mea
sure
men
tM
easu
rem
ent
10
0%
10
0%
10
0%
10
0%
10
0%
As
per
Dra
win
gG
ood C
onditi
on
Hea
ter
coil
should
not be
open
As
per
Dra
win
gO
per
atio
n &
Curr
ent
dra
wn
IR IR PCR
P P P P P
18
19
.
Air L
oad T
est
As
per
Ther
max
Standard
Form
at
Ener
gis
ing T
R
panel
s &
TR s
ets
with
ESP
fie
lds.
10
0%
As
per
Pre
-co
mm
issi
onin
g R
eport
20
.PP P W W W W W
WW W R R R R R
10
0%
To r
ate
d v
alu
e o
f prim
ary
&se
condary
vo
ltage
As
per
ele
ctric
al w
irin
g
dia
gra
m
By
keep
ing T
R
-ve
bush
ing o
pen
Funct
ional oper
atio
n
chec
kPC
RW
Sr. N
o
Note
on L
eak T
est
Pro
cedure
:
A) A
fter
com
ple
tion o
f all
mec
hanic
al er
ectio
n a
ctiv
ities
and b
efore
sta
rtin
g a
pplic
atio
n o
f in
sula
tion,
leak
test
is
to b
e ca
rrie
d o
ut. T
his
is
to e
nsu
re that th
ere
are
no w
eldin
g lea
kages
in the
ESP
.
B) A
fter
ESP
is
boxe
d u
p,
i.e.
after
fix
ing a
ll acc
ess
doors
, ra
pper
sea
ls,
insu
lato
r hea
ters
, th
erm
ost
ats
, hopper
lev
el p
robes
, bla
nk
ESP
inle
t
a
nd o
utle
t ei
ther
by
closi
ng the
dam
per
s (if th
ey a
re a
vaila
ble
) or
by
fixin
g a
bla
nki
ng p
late
with
its
sea
l w
eldin
g.
Connec
t th
e Pu
rge
Air
b
low
er d
irec
tly to the
pen
thouse
. Bla
nk
all
oth
er o
pen
ings
e.g.
hopper
outle
ts e
tc.
in the
ESP
by
dum
my
pla
tes.
C) Th
en s
tart the
Purg
e air b
low
er a
nd p
ress
urise
the
ESP
upto
10
0m
mW
C.
D) Po
ur
the
soap w
ate
r on a
ll si
te w
eld join
ts (w
ith the
hel
p o
f w
ate
r tu
be)
and o
bse
rve
for
any
bubble
foam
. In
case
of w
eld join
t le
aka
ge
bubble
will
be
form
ed.
Mark
all
such
poin
ts a
nd w
eld them
. Rep
eat til
l no lea
kages
are
obse
rved
. D
uring this
tes
ting k
eep s
uffic
ient st
ock
of so
ap w
ate
r (a
ppro
x. 3
0 lite
rs) ove
r pen
thouse
.
Legends:
P -
Perf
orm
; W
-W
itness
; R-
Revi
ew
; IR
-In
spect
ion R
eport
; PC
R-
Therm
ax'
s Pre
Com
mis
sionin
g R
eport
s
18
Installation & Commissioning Manual ELECTROSTATIC PRECIPITATOR
Chapter 8
Guidelines on ESPPre-Erection Activities
ELE
CTRO
STA
TIC
PREC
IPIT
ATO
R
19
Guidelines on ESP Pre-Erection Activities
A. Foundation checking :
Following steps are to be followed while checking the civil foundations. Refer schematic sketch nos. 002 to 005 for
reference.
a. Extend the plant centerline / main equipment centerline (both X & Y-axis) and bench mark (i.e. datum-line)
between ESP footings.
b. Transfer these centerline (X & Y axis) on respective ESP footings.
c. Check the foundation bolt pockets of individual footing w.r.t. these centerline. Repeat this procedure for all
footings.
Once marking of centerline on all footings is completed, the axial and diagonal measurements are to be
checked and maintained within the tolerances mentioned in table.
Sl.
No.
Description Allowable Deviation
1 Axial measurement in X & Y axis + / - 5mm
2 Diagonal measurement (Overall)
– In plan view
1mm/mts or 8mm (whichever is min.)
3 Diagonal measurement
(Individual footing) – In plan view
1mm/mts or 8mm (whichever is min.)
4 Elevation + / - 10mm either side. The variation to be
adjusted either in packing pates or by
foundation chipping
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
Installation & Commissioning Manual ELECTROSTATIC PRECIPITATOR
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.
Procedure for making template
After checking the foundation & its pocket's alignment, the templates are required to cast the foundation bolts
in their respective pockets. These templates can be fabricated using sheet / plate with min. 2.5mm thick.
(Size (WxL) should be similar to the size of the structure base plate.)
+Take MS sheet / plate and make the following markings.
+Mark the centerline along axis XX and YY.
+Mark the center distances of the holes as per hole dimensions of support structure base plates. Punch these
centers and drill holes. The hole diameter shall be similar to the hole size in support structure base plate.
ii. Based on above (i), calculate out the thickness of the packing plates required to maintain the support structure
base plate level and place them on the foundation. The number of packing plates should be kept minimum by
providing the higher thickness packer to avoid multiple packing plates. These packing plates should be stitch
welded with each other, after ESP's bearing alignment and before grouting.
While placing the packing plates, ensure that minimum 50mm grouting clearance is available between
foundation top and template / support structure base plate. If sufficient clearance is not available, foundation
top face should be chipped out to have this clearance.
iii. In this process, ensure that thread length equivalent to minimum 2.5 times of foundation bolt diameter is kept
above template (i.e. top of support structure base plate).
iv. Align the templates i.e. center markings on templates, [with foundation bolts (in both X & Yaxis)] with the
markings on ESP footings, made earlier during foundation checking.
Then lock the template with foundation in such a way that the foundation bolt alignment will not be disturbed
during pocket grouting.
v. After ensuring the foundation bolt alignment and template locking, pour the grouting cement in pocket.
Always use NSG type grouting cement. While pouring the grouting cement, keep the foundation bolt rotating
to allow releasing the trapped air.
WHILE GROUTING THE POCKET, ONLY HALF OF THE POCKET SHOULD BE GROUTED. This is to
have little flexibility to adjust the deviations in support structure base plate hole centers (if any), during erection
of support structure.
vi. Remove the template after grouting cement's curing.
Repeat such procedure for all other foundations.
f. After completing the foundation bolt grouting, check & ensure the alignment of all foundation bolts w.r.t. axis,
elevation (as referred above), diagonals (individual footing & over all).
20
Installation & Commissioning ManualELECTROSTATIC PRECIPITATOR
21
Installation & Commissioning Manual ELECTROSTATIC PRECIPITATOR
Sketch No. 002 Footing Center Line Marking
Sketch No. 003
22
Installation & Commissioning ManualELECTROSTATIC PRECIPITATOR
Sketch No. 004 Footing Center Line Marking
23
Installation & Commissioning Manual ELECTROSTATIC PRECIPITATOR
Sketch No. 005 Foundation Alignment Protocol
B. Verification of the ESP Material Received:
All ESP materials are dispatched in CKD condition. All these materials are dispatched in different stages. Hence the
verification is essential, prior to its assembly and erection.
For this, all the materials must be checked w.r.t. the packing slips / loading reports and bill of material.
Any deviation found must be informed to Thermax Ltd. Enviro Division within 7 (Seven) days from the receipt of
material.
C. Ground Assembly of ESP Parts:
After verification of material, ground assembly of following ESP parts can be done and kept ready for erection
a. Inlet Nozzle with gas distribution screen
b. Outlet Nozzle with gas distribution screen
c. Casing columns with casing panels
d. Hoppers
e. Penthouse side panels with columns
f. Top HV Frame
General Instructions:
Prior to start of ground assembly work of ESP items -
1. Check the available material w.r.t. BoM & ensure that all items are available at site as per BoM.
2. Arrange for the leveled ground / surface for ground assembly of ESP items.
3. All ground assembly works are to be carried out on a leveled surface. This is required to maintain the quality
of the material being assembled.
4. Ensure the availability all needed resources like catagorised manpower, material-handling equipment like
hydra / crane (of sufficient capacity), other tools & tackles, prior to respective part's assembly.
5. All seal weld joints must be checked for its leakages with help of kerosene test. The brief procedure of
kerosene test is explained below.
Kerosene Test:
+Apply lime paste on lower surface of the weld joint. Allow it to dry.
+After drying the lime paste, spray kerosene on top / upper side of weld joint i.e. where lime paste is not
applied.
+ Any missed out welding / blow hole etc. will be indicated by a wet patch on the lime paste.
+Based on the weld defects, trace out the defects and repair it by grinding and welding. After repair, do the
testing again at repaired locations. It is advisable to carry out leak test as soon as the welding is completed
and before the scaffolding / staging is removed from a particular area.
+The welding portion which are checked and found ok during assembly stage, need not to test again after
erection. Similar procedure of kerosene should be followed for site weld joints.
24
Installation & Commissioning ManualELECTROSTATIC PRECIPITATOR
Following is the brief procedure about the assembly of above parts.
D. Inlet Nozzle with Gas Distribution Screen
1. All inlet nozzle components are supplied in CKD condition to facilitate the easy transportation of nozzle
material.
2. Depending on the capacity of available lifting equipment, assemble the nozzle either in one piece or in two
pieces.
3. Approx. 800mm ground clearance is to be provided between leveled surface and nozzle's bottom edge, for
access (for man & cables) & for proper ventilation inside the nozzle, during assembly.
4. Please refer and study the inlet nozzle assembly drawing, sent separately.
5. Place the nozzle panels, as shown in attached sketch no. 006 and join them. While placing the panels, ensure
that the panel's stiffener sides are kept at lower end.
6. While assembling the nozzle, refer the reference drawing (sent separately) and attached schematic sketch
nos. from 079 to 082
7. During assembling the nozzle, ensure that all inside pipe supports / bracings are provided at correct
locations, as shown in referred drawing.
8. Prior to start seal welding, check and ensure the nozzle opening dimensions (including diagonals) 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)
9. After welding, all weld joints are to be checked for any visual welding defects (e.g. blow holes / left out
welding) and to be rectified, if any defects found.
10. After weld rectification of defect, all weld joints are to be tested for its leakages by kerosene test method. If any
leakages are found, same to be rectified.
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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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.
E. Outlet Nozzle with Gas Distribution Screen
For outlet nozzle & its GD screen ground assembly, similar procedure / steps shall be followed, as to that of inlet
nozzle & its GD screen.
F. Casing columns with Casing panels
To avoid hectic position fit-up and welding of casing panel with casing column, the casing 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 at erection spot.
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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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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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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Sketch No. 006 Nozzle Assy Panel Fit-Up
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Sketch No. 007 Casing Column Assembly (With Side Panel)
9 10 11
12 13
Sketch No. 008 Casing And Hopper Fit-Up Details
Installation & Commissioning Manual ELECTROSTATIC PRECIPITATOR
31
15
1617
18 19
Sketch No. 14 Casing And Hopper Fit-Up Details
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32
Sketch No. 20 Casing And Hopper Fit-Up Details
Sketch No. 21 Sketch No. 22
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Sketch No. 23 Hopper Assembly Fit-Up
Sketch No. 24 Sketch No. 25
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Hopper Assembly Fit-Up
Sketch No. 27
Sketch No. 29Sketch No. 28
Sketch No. 26
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Top High Voltage Support Frame Welding Details
Sketch No. 30
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Chapter 9
Guidelines on ESP Mechanical
Erection Activities
ELE
CTRO
STA
TIC
PREC
IPIT
ATO
R
Guidelines on ESP Mechanical Erection Activities
The list of activities involved in ESP erection and commissioning is briefed in chapter 7, as main activities and
parallel activities, in a proper sequence.
Those activities are briefed below, to help and guide the ESP erection.
A. Foundation Checking
Please refer the foundation checking description in pre-erection activities.
HOLD POINT: UNLESS UNTIL THE FOUNDATION INSPECTION IS CHECKED AND ACCEPTED, FURTHER
ERECTION OF ESP SUPPORT STRUCTURE SHOULD NOT BE STARTED.
B. Support Structure Erection, Alignment and Welding
a. For erection, alignment & welding of support structure, refer support structure drawing sent separately
alongwith the attached schematic sketches (nos. from 031 to 032).
b. After completion of foundation checking and foundation bolt grouting, the support structure erection shall be
started.
c. Do the micro chipping of the foundation top surface, where the packing plates are to be placed.
d. While doing the support structure alignment, the elevation of support structure is to be maintained at top of
the structure. Considering this and length of the individual columns, calculate the total thickness of packing
plates required to get the support structure top at same elevation.
e. Place the required packings on individual footings and then place the column on respective footing. While
placing the column on footing, the due care of safety to be taken, to avoid the accidents due to fall of
columns. Once the columns are placed on individual footings, the columns to be secured by fixing the nuts to
the foundation bolts.
f. After placing all columns on their respective footings, fix the tie bracings of support structure. At this stage, the
bracings should be bolted only. Welding of bracings should not be carried out at this stage.
g. Once the bracing are fixed as per drawing, the alignment of support structure should be done for column's
verticality, column's center distances (axial & diagonal).
Following guidelines, on allowable deviation, shall be followed for acceptance of support structure alignment
Sl. No. Description Allowable Deviation
1 Axial measurement
in X & Y axis
+ / - 5mm
2 Diagonal
measurement
(Individual / Overall)
1mm/m or 8mm (whichever is min.)
3 Verticality / Plumb + / - 1mm per meter either side and max.
10mm (whichever in minimum). The variation
to be adjusted in packing pates below support
structure columns.
4 Level of column top +/ - 2mm w.r.t. fixed bearing column
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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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Support Structure Alignment
Sketch No. 31
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Structure Column Erection
Sketch No. 32
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Sketch No. 111
Structure Site Welding
TYPICAL SITE WELDING DETAILSFOR SUPPORT STRUCTURE / MONORAIL STRUCTURE
C. Bearing Installation and Alignment
i. The bearing installation and its alignment can be started, only after completion of support structure alignment
& its acceptance.
ii. The bearing alignment it to be carried out as per the bearing layout drawing and w.r.t. fixed bearing. For this
purpose, refer the bearing layout drawing sent separately alongwith typical sketch nos. 033 to 035, attached
with this.
iii. Prior to installation of bearings, ensure the structural distances (axial & diagonal) are as per drawing and are
within acceptable tolerances, as briefed in support structure erection & alignment.
iv. Fix the respective bearings (i.e. Fixed bearing, Mono-axial bearing X & / or Y direction, Bi-axial bearings), as
per drawing on top of support structure.
v. Check the bearings for following
a. For its correct center distances (structure / cold condition) in both axial and diagonal direction.
b. For its correct water level i.e. elevation.
c. For its correct spirit level
vi. The bearing alignment must be checked w.r.t. FIXED BEARING ONLY.
vii. Following guideline shall be considered for acceptable tolerances of bearing alignment.
Sl. No. Description Allowable Deviation
1 Axial measurement in X & Y axis
2 Diagonal measurement
(Individual / Overall)
3 Elevation of column top
4 Spirit level of bearing top plate
+ / - 2 mm
1 mm/m or 5 mm (whichever is min.)
+/- 2 mm w.r.t. fixed bearing column
Correct spirit level
The typical check point list is as given in below table.
Bearing No. A1 B1 A2 B2
Inspection Point
Spirit Level
Water Level w.r.t. Fixed Bearing
A3 B3 A4 B4
Mark 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.
v
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Expansion Bearing Assembly
Sketch No. 33
Sketch No. 34
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Expansion Bearing Alignment
Sketch No. 35
D. Casing Erection, Alignment and Welding
i. After completion of bearing alignment and its locking, the erection of casing panel / column assembly should
be started.
ii. Shift the assembly nearer to erection point.
iii. Prior to starting the erection work, all safety points / risks, involved in erection of casing panel & column
assembly are to be reviewed and accordingly further needed precautions are to be taken.
iv. Deploy the crane (lifting equipment) of sufficient capacity at erection spot.
v. Ensure the availability of sufficient clear space, around crane and then make the needed arrangement for
lifting the assembly.
vi. After lifting the assembly, dry run of the crane should be conducted and then further lifting of assembly should
be done.
vii. After placing the assembly on respective bearings, it should be tied properly using guy ropes, at least two on
each side, to avoid its falling when it is released from crane.
viii. Once the assembly is positioned, secured by guy ropes and released from crane, make preparation to lift the
opposite side assembly, in a similar way to that of first one.
ix. After positioning the two opposite side assemblies, erection of respective top and bottom girders shall be
done. This will form a box structure of erected assemblies and will have better stability.
x. Repeat the above sequence for other assembled casing columns & panels / respective top & bottom girders.
xi. Once all assembled casing column / panel, top / bottom girders are positioned, the alignment of the
columns can be done for its plumb (verticality) and axial / diagonal measurements.
Following guidelines shall be followed for acceptable tolerances
Sl. No. Description Allowable Deviation
1
2 1mm/mtr or 8mm (whichever is min.)
3 Verticality / Plumb
4 Level of column top . fixed bearing column+/- 3mm w.r.t
Axial measurement in X & Y axis
Diagonal measurement (Individual / Overall)
+ / - 5mm
+ / - 1m/mtr either side and max. 10mm(whichever in minimum). The variation to be adjusted in packing pates below support structure columns.
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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Casing Column Alignment
Sketch No. 36
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Casing Column & Top Girder Alignment
Sketch No. 37
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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Staircase, Railing, Landing Fit-Up
Sketch No. 38
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Staircase, Railing, Landing Fit-Up
Sketch No. 39 Sketch No. 40
Sketch No. 42Sketch No. 41
F. Erection and alignment of Collecting Plate Floating Channel arrangement
i. For alignment of collecting plate floating channels, refer the drawing sent separately with the attached
schematic sketch no. 043 & 044.
ii. The collecting plate floating channels can be fixed to the respective top girders and locked on ground, before
erection of top girders.
iii. For doing the floating channel alignment and its inspection, the temporary platform with approach ladder to
floating channel location is to be made available.
iv. Following points are to be checked / ensured while doing the floating channel alignment.
a. Plumb of the roof bolts. All the roof bolts must be in plumb (without any deviation), in its free hanging
condition with floating channel.
b. Center to center distances (axial & diagonal) of roof bolts. The center to center distances of roof bolts
of respective field must be as per drawing and within tolerances. The axial distances must be kept within +/
-2mm and diagonal distances must be kept within +/- 4mm. All center distances should be measured w.r.t.
ESP center line.
c. Water level of floating channels. All the floating channels of respective fields must be kept in water level
with acceptable tolerances of +/- 2mm.
v. The floating channel alignment readings should be recorded as shown in sketch no. 044.
vi. After floating channel alignment completion and its acceptance, they should be locked temporarily with
adjacent girder, to avoid its swaying.
HOLD POINT: TILL FLOATING CHANNEL ALIGNMENT IS ACCETED, FURTHER ERECTION OF
COLLECTING PLATE ASSEMBLIES SHOULD NOT BE STARTED.
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Floating Channel Alignment
Sketch No. 43
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Floating Channel Alignment
Sketch No. 44
G. Assembly of Collecting Plate Panels
i. The collecting plate assemblies should be done on assembly jig and assembly jig should be placed on a
leveled surface. The schematic sketch of such assembly jig is shown in attached sketch no. 046.
ii. The assembled collecting plates should not be stacked for longer period. Otherwise the assembled plates
would get bow while they are stacked. Hence collecting plate assembly activity should be started in such ways
that whatever collecting plates are assembled, should be erected by next day.
iii. The distance between assembly point and erection spot should be as minimum as possible. This is to avoid the
damages to the collecting plate assembly during shifting.
iv. Before starting the collecting plate assembly, the collecting plate bundles should be shifted near the assembly
point.
While shifting the collecting plate crates, always use spreader beam and lifting hooks of crate. Also while
stacking the crates, ensure that the collecting plate profile is in vertical direction.
v. While cutting the collecting plate bundle, sufficient care is to be taken to avoid fire catching of crate packing
material. Also the cutting set flame direction should be always away from the crate. Otherwise these both
things may result in damages to the collecting plates due to excess heat of fire or cutting set.
vi. Before starting collecting plate assembly, each collecting plate should be checked for its straightness. For this
purpose, fabricate a straightness checking jig as shown in sketch no.045.
a. Insert the collecting plate in this straightness-checking jig. If the plat is straight within 2mm of tolerance, it
fits in the jig freely and such plates can be used for assembly.
b. If plate is bend, it does not fit freely in the straightness-checking jig. Such plate needs to be straightened
with the help of wooden mallet or fiber tip mallet. The hammering is to be done on both upper and
lower end of the collecting plate edges.
c. For bend plates, the light hammering should be done in opposite direction of the bend and hammering to
be done on the edge of collecting plates. UNDER ANY CIRCUMSTANCES HAMMERING SHOULD NOT
BE DONE ON COLLECTING PLATE PROFILE.
The straightness can be checked with the help of thread line or visually (by skilled person). Similar process
should be repeated for other(lower) side of the plates.
Once the plate become straight, it will become free in the straightness checking jig and then it is ready for
assembly.
d. By ensuring the plate straightness before its assembly, lot of re-work on collecting plate (after erection) can
be avoided.
vii. Below mentioned sequence should be followed for collecting plate assemblies.
a. Refer the assembly jig drawing (sent separately) and attached schematic sketch no. 046. Accordingly
assemble the jig. While doing assembly, dimensional measurements as per drawing, including diagonals
should be ensured. Also ground, clearance of approx. 800-900mm should be maintained, for
movement of persons for welding of collecting plate assembly.
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Collecting Surface Straightening Tool
Sketch No. 45
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
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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Collecting Plate Welding Details
Sketch No. 47
Sketch No. 48
H. Erection of Collecting Plate Assemblies ( By Crane / By Winch)
Depending on the site condition and lifting arrangement facility, the collecting plate assemblies can be erected by
two methods.
I. By Winch (Manual or Electric) and
II. By Crane
Both the above guidelines are described below in brief.
Following are few common activities that need to be completed before starting the plate assembly erection.
i. The collecting plates assemblies are very light weight compared to its size. Hence collecting plate
assembly erection must be done using lifting frame. For this purpose prepare (fabricate) the lifting
frame, as per the drawing sent separately. The typical sketch of such lifting frame is attached with this as
sketch no. 049.
ii. Ensure that at least 10 collecting plate assemblies are assembled, checked ok and ready for erection.
iii. Before starting the plate assembly erection, welding of casing panel to column / top & bottom girder
with column should be completed.
iv. Alignment of floating channels is to be completed before starting plate assembly erection.
v. No man movement should be allowed below the area / field, where collecting plate assembly lifting or
erection is going on. Safe working barricades should be provided while erection is in progress.
I. By Winch (Manual or Electric)
Following are the brief guidelines for erection of collecting plates by winch. Normally by this method,
collecting plate assemblies are erected from ESP bottom area.
a. Check and ensure that sufficient ground clearance is available below ESP, for easy lifting of the
collecting plates with its lifting frame.
b. Ensure that no structural bracing fouls in the way of plate assembly lifting. In case any bracing fouls, it
may be removed temporarily, after consulting with the authorised person and it should be fixed back
immediately at its original position after completing the erection work.
c. Depending on the size / model of ESP, the weight of collecting plate assembly varies. However it is
always preferred to have approx. 4.0 MT capacity winch (Mechanical / Electrical) for erection of
collecting plate assemblies.
d. For lifting the plate assembly, fabricate a box channel from ISMC 200, as shown in sketch no. 051. This
channel box is suitable for lifting the plate assembly weight upto 3.5 MT (incl. weight of lifting frame). In
case of higher weight, higher section like ISMC 250 or ISMC 300 shall be used.
e. The lifting equipment (winch) and material handling items (e.g. wire rope, slings, rope pulleys, D-
shackles 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 valid test
certificates must be made available before they are used for work.
f. The winch rope should be in good and lubricated condition. The rusty ropes should not be allowed to
use.
g. Always keep the material handling equipment (i.e. winch) outside and at safe distance from lifting area.
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Erection Tools
Sketch No. 49
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Lifting Frame With Panel Assy.
Sketch No. 50
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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Lifting Arrangement For Collecting Plate Assy.
Sketch No. 51
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.
I. Alignment of Collecting Panels
Once the collecting plate erection is completed, alignment of collecting plates to be done.
Following are the check points of collecting plate alignment .
i Plumbness of collecting plates
ii. Spacing of the collecting plates.
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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ii. Spacing of the Collecting Plates.
a. After checking & ensuring correctness of collecting plate plumbness, the collecting plate spacing to be
checked.
b. Check the spacing of collecting plates, as per GA drawing, at both top and bottom of the plate
assemblies.
c. In case on any minor variation in spacing, especially at collecting plate bottom, it can be rectified by
adjusting bottom tie bar.
d. After correcting the spacing, the readings shall be recorded.
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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Collecting Plate Plumbness
Sketch No. 52
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Collecting System Fit-Up Details
Sketch No. 53
Sketch No. 55
Sketch No. 56
Sketch No. 54
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Collecting System Fit-Up Details
Sketch No. 57 Sketch No. 58
Sketch No. 60Sketch No. 59
Sketch No. 61
J. Positioning of top HV frame with other HV system components
a. After completing collecting plate alignment, top HV frame should be kept in position on temporary
supports.
b. The temporary supports shall be taken from casing panel and adjacent girders. For this purpose the
channel brackets (ISMC100 /150) shall be used. Refer the attached schematic sketch no. 063.
c. Normally the gap between collecting plate top tadpole (top side) and of top HV frame (bottom side) is
kept between 267mm to 290mm. While welding the temporary supports, this gap is to be ensured, so
that correct positioning of top HV frame is done.
d. Ensure the correct water level of temporary support brackets. If water level is not ensured, all further
activities related to top HV frame would go wrong.
e. After welding of temporary support brackets at correct water level, placetop HV frame on it. This can be
done by crane or winch. While lifting top HV frame, sufficient care should be taken to avoid its slipping
resulting in major accident & / or damages to the material.
f. While positioning the top HV frame on temporary support brackets, ensure that position of corner
regitrode mounting hole location is at center of respective gas passage or collecting plates. This is
described in attached schematic sketch no. 075.
K. Erection, Fit-up and Welding of Inner Roof
a. Once top HV frame is positioned, inner roof plate can be erected and welded as per roof plate
arrangement drawing, sent separately. For typical fit up details of roof plates, refer attached schematic
sketches nos. from 009 to 019.
b. Ensure the proper fit-up and seal welding of plate joints. All plate joints are to be seal welded from
outside and stitch welded from inside.
c. After completing of roof plate welding, check the weld joints for weld defects and rectify it, if any
leakages found.
d. After rectification of weld joint, check the welding for its leak test, using kerosene test.
L. Erection, Alignment and Welding of ESP Penthouse
After erection, fit-up and welding of inner roof, penthouse erection can be started. For this purpose refer the
penthouse drawing sent separately along with typical fit up details shown in attached schematic sketches nos.
from 064 to 066.
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*
*
H.V. Assembly Suspension
Sketch No.63
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Penthouse Fit-Up Details
Sketch No. 64
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Penthouse Fit-Up Details
Sketch No. 65
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Penthouse Fit-Up Details
Sketch No. 66
M. Installation and Alignment of Support Insulator and its allied parts:
After completion of penthouse erection, erection of HV components like HV rapper rod, Support insulators,
slide base plate, insulator flange plate etc. shall be done.Below mentioned sequence should be followed for
erection and alignment of support insulator and it's allied parts. For this purpose, refer attached schematic
sketches nos. from 067 to 073.
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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Rigitrode System Fit-Up Details
Sketch No. 67
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Sketch No. 68
Rigitrode System Fit-Up Details
Sketch No. 69
Sketch No. 70 Sketch No. 71
Sketch No. 72 Sketch No. 73
N. Erection of rigitrodes to top HV frame and its straightness checking
After ensuring top HV frame alignment, regitrode erection can be started. Following guideline shall be followed for
regitrode erection.
1. If sufficient ground clearance is available, regitrodes can be erected from ESP bottom.
2. If sufficient ground clearance is not available, regitrode are to be erected from ESP top, before erection
of penthouse.
1. Erection of regitrode from ESP bottom
a. Check availability of sufficient ground clearance.
b. If sufficient clearance is available, regitrodes can be erected one by one with the help of manila rope
with a J-type hook.
c. Tie a rope pulley on ESP roof / girder member with help of lug.
d. Pass a manila rope of sufficient length, through this pulley and bring both ends of manila rope on
ground. Tie J-type hoof, fabricated from a plain MS rod of 10 to 12mm diameter. The open end of J
book should be in such a way that easy & trouble free hooking & removal of regitrode is possible. The J
type hook should be tied & secured firmly with manila rope in such a way that, it should not slip / fall
down which may result in any kind of accident.
e. Once above briefed lifting arrangement is ready, one regitrode can be lifted carefully to check the
smooth lifting of regitrode.
Before erection of regitrodes, check the spikes/pins straightness of all electrodes. DO NOT ERECT THE
REGITRODES WITH BEND PINS/SPIKES. After lifting the regitrode, it has to be taken to its respective
position to bolt it to top HV frame. Since straightening of bend regitrodes would become additional
time-consuming activity at fag end of ESP erection, straightness of regitrodes must be ensured before
regitrodes are fixed to top HV frame. Normally regitrodes gets bend due to its mis handling. While
handling the regitrodes, 3-4 workmen should be used at appropriate distances. Also while lifting the
regitrode, the regitrode should not be kept /hold in slant /angular position. Both these thing will help to
avoid regitrodes getting bend.
No man movement should be allowed below the area / field, where regitrode erection is going on. Safe
working barricades should be provided while regitrode erection is in progress.
f. After ensuring the safe & proper erection of first regitrode, repeat the similar procedure for erection of
further regitrodes.
g. Once regitrode erection is completed in a field, the regitrode straightness checking should be stared.
The regitrode straightness should be checked in its free hanging condition and it should be within +/
5mm either side. The straightness of the regitrode can be normally checked visually by ESP supervisor.
To check bow of regitrode accurately the gauge similar to “T” gauge can be used.
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Rigitrode Lifting Frame
Sketch No. 74
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.
2. Erection regitrode from ESP top
a. Check availability of top clearance for erection regitrodes from ESP top. Always check the capacity & sufficient
boom length of the crane, before starting regitrode erection from ESP top.
b. To avoid bending of regitrodes during its erection, a temporary frame of ISMC 150 or 200 should be
prepared, as shown in sketch no. 074. The length of such frame shall be kept similar to regitrode length, with
facility to fix 8 to 10 regitrodes.
c. After lifting the frame with regitrodes, it should be taken inside the ESP through roof access door and from their
individual regitrode should to be taken to the respective place and then to be bolted to top HV frame.
d. As briefed above, bending of the regitrodes should be avoided. Also while lifting the frame with regitrodes,
frame should not be kept /hold in slant / angular position for longer period.
e. No man movement should be allowed below the area / field, where regitrode erection is going on. Safe
working barricades should be provided while regitrode erection is in progress.
f. After ensuring safe erection of first regitrode set, repeat the similar procedure for erection of further
regitrodes.
g. Once regitrode erection is completed in a field, the regitrode straightness checking should be started as
briefed above.
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 regitrode straightness, bottom guide frame shall be fixed to regitrodes bottom.
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O. Alignment of regitrodes w.r.t. collecting plates
The field alignment (i.e. checking the gap between collecting plate profile w.r.t. adjacent regitrodes) should
be started, after straightness checking of regitrode and erection of bottom frame.
Following are the important guidelines on alignment of regitrodes w.r.t. collecting plates
a. Refer the schematic sketch no. 075 (Detail view). As shown in plan view, the position of regitrode center, at
four corner of the field (i.e. at 4 locations) is to be ensured w.r.t. adjacent collecting plates. Such checking
should be done for all fields of ESP and readings are to be recorded as per below mentioned table no. 1.
Following dimensional measurements are to be ensured.
Gas Passage Width “A” or “B” min
305mm i.e. 12”
406mm i.e.16”
152mm or 6”
178mm or 7”
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.
Gas Passage Width
Minimum clearance required between Regitrode pin to Collecting Plate surface
At Top & Bottom Locations of approx. 1000mm of regitrode length
At middle and other locations of regitrode
305 mm or 12”
406 mm or 16”
148mm
198mm
136mm
190mm
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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Collecting Plate & Rigitrode Clearances
Sketch No. 75
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 No.
At Top of Field At Bottom of Field
No. 1
No. 2
No. 3
No. 4
A B C D E F A B C D E F
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Table No. 1: Format for recording collecting plate and regitrode alignment readings:
GP No. At Top of Field At Bottom of Field
1
2
3
4
E F E F
5
6
7
8
9
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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P. Erection, Fit-up and Welding of Casing Baffle Plate
a. After completion of field alignment, casing baffle plates are to be installed.
b. The typical schematic arrangement of casing baffle plate is shown in attached sketches no. from 076 to 078.
c. All casing baffle plates should be seal welded with casing panel at one side, where the access is available.
d. The baffle plates should start from bottom side of the top girder and should end at top side of the bottom
girder. No gaps should be left out between baffle plate and any girder / casing panel. This is very important to
stop the gas sneakage, hence better performance of ESP.
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Casing Baffle Arrangement
Sketch No. 76
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Casing Baffle Arrangement
Sketch No. 77
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Casing Baffle Arrangement
Sketch No. 78
Q. Erection, Alignment and Welding of Inlet Nozzle with GD Screen
Inlet nozzle comprises of nozzle plates in assembled form, perforated sheets no. 1, 2, and 3 (as applicable),
guide vanes / ladder vanes (as applicable).
Inlet nozzle can be erected in two ways.
A. By assembling the nozzle, with GD screen on ground and erecting the entire unit, by crane (If suitable crane /
sufficient space is available at site).
B. By erecting the nozzle panel by panel. Since manual erection of heavy items is becoming outdated, this part is
not briefed in this guideline.
For erection of nozzle, refer the reference drawing sent separately along with typical schematic sketches no. from
079 to 090.
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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Inlet & Outlet Nozzle Assy. Fit-Up
Sketch No. 79
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.
R. Erection, Alignment and Welding of Outlet Nozzle with GD Screen
The outlet nozzle comprises of nozzle, perforated, guide vanes / ladder vanes (as applicable).
In most of the cases, ESP outlet nozzle is identical to the inlet nozzle. Hence, follow similar steps of inlet nozzle
assembly erection for erection of outlet nozzle also.
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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Inlet & Outlet Nozzle Assy. Fit-Up
Sketch No. 80
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Inlet & Outlet Nozzle Assy. Fit-Up
Sketch No. 81 Sketch No. 82
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Inlet & Outlet Nozzle Rapping Fit-Up
Sketch No. 83
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Inlet & Outlet Nozzle Rapping Fit-Up
Sketch No. 84
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G. D. Screen Assy. Fit-Up
Sketch No. 85
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G. D. Screen Assy. Fit-Up
Sketch No. 86 Sketch No. 87
Sketch No. 89
Sketch No. 90
Sketch No. 88
S. Erection of Hopper and its allied parts / Hopper Maintenance Platform
a. Hopper erection should be started after erection of regitrode and its bottom frame.
b. Since fields are filled with internals, erection of the hopper is to be done manually, by chain block of suitable
capacity. Minimum two chain blocks, of suitable capacity, should be used for erection of each hopper. All
lifting equipment i.e. chain blocks / tackles, dshackles, slings those are being used for erection purpose,
should be tested for their safe capacity and such test certificates should to be made available prior to erection
of hopper.
c. For erection of hopper refer hopper drawings sent separately along with schematic sketches on. 020 to 025
and 091 to 093.
d. For erection of hopper, lifting lugs are to be welded on bottom girders, at suitable location i.e. at equi -
distance from ESP centerline, so that load of hopper can be distributed on bottom girders equally.
UNDER ANY CIRCUMSTANCES, THE ESP INTERNAL MEMBERS SHOULD NOT BE USED FOR ANY
LIFTING PURPOSE. OTHERWISE ESP INTERNALS WOULD GET DAMAGED.
e. Also lifting lugs are to be welded on inside faces of the hopper plates, at identical location to that of lugs
welded on girders. Here lugs should be welded on hopper plate with a pad plate and ensure that at opposite
end of such location, hopper plate stiffener present.
f. Once lifting lugs are welded on girders and hopper plates, the assembled / semi-assembled hoppers can be
shifted below respective field and keep them ready for lifting.
g. After readiness of hopper lifting arrangement, hopper lifting shall be done. Prior to entire lifting, the dry run of
chain pulley block shall taken.
h. Once hopper is fixed to its position, fitting and welding (at least stitch welding e.g. 400-300-400) should be
done. The chain pulley blocks should not be removed, until hopper fitting and its welding is completed.
i. Similar steps should be followed for erection, fit-up and welding of other hopper assemblies.
j. While erecting hopper lower portion, ensure the elevation of hopper outlet flange (as per drawing)along with
its water level.
k. After welding, hopper weld joints (panel to panel & corner) are to be checked for welding defects and then
rectification to be done, if any defects are found.
l. After attending welding defects, kerosene test of hopper weld joints to be done, to ensure leak proof weld
joints.
m. After successful kerosene test, hopper corner flat should be welded, as shown in sketch no. 023.
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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Hopper Baffle Arrangement
Sketch No. 91
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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Hopper Baffle Arrangement
Sketch No. 92
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Casing And Hopper Fit-Up Details
Sketch No. 93
T. Erection of Monorail with its structure
The monorail erection should be done after complete erection of penthouse (incl. fit up and welding).
For erection of monorail, refer Monorail drawing (sent separately) with typical sketche nos. 094 attached with this.
The monorail can be erected with the help of crane.
In case, if crane is not available, erection can be done with the help of small derrick. Such derrick needs to be moved
from one position to another, as required.
The erection sequence of monorail with its structure remains similar whether it is erected by crane or by derrick.
Following is brief sequence for erection of monorail with its structure.
a. Fix monorail structure columns as shown in reference drawing.
b. Bolt the structure bracings as per drawing.
c. Do the alignment of structure columns. For acceptable tolerances, follow the guidelines given in ESP support
structure alignment.
d. After completing structure alignment, complete the structure welding as per drawing and then erection &
welding of monorail beam should be done. Ensure that stoppers at both free end of monorail beam are
welded, as shown in reference drawing.
e. The chain block with trolley should be fixed with monorail beam, once it is erected (incl. welding of stoppers at
both free end of monorail beam.)
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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Monorail Structure Assembly
Sketch No. 94
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Structure Site Welding
Sketch No. 111
TYPICAL SITE WELDING DETAILSFOR SUPPORT STRUCTURE / MONORAIL STRUCTURE
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High Voltage Assy. With T/R
Sketch No. 95
U. Erection of TR (Transformer Rectifier) set with base frame and HV Ducting
The TR set with its base frame & HV duct should be done after completion of penthouse (erection & welding).
The TR sets can be erected either by crane or by monorail. In case of TR set erection by crane, first TR sets should be
erected followed by monorail with its structure. However, in case of TR set erection by monorail, first monorail
erection (with welding) to be completed followed by TR sets.
In the both above cases, the erection sequence remains same.
a. Refer the drawing sent separately for erection of TR sets with its HV ducting along with attached schematic
sketch no. 095 & 96.
b. First fix TR set base frame, as shown in referred drawing.
c. Place the TR sets on this base frame. Ensure that correct rating TR sets are installed at their respective fields.
For this purpose always refer the ESP’s GA drawing, where in field wise location of TR sets is given.
d. While erecting TR set, necessary safety precautions are to be taken to avoid the damages to the TR set and its
items like silica gel breather / bucoltz relay / dial thermometer etc.
e. Only tested lifting tools should be used while erecting the TR sets.
f. After placing TR sets at their position, fix HV duct, as shown in referred drawing. The typical sketch of HV duct
connection (with TR set and with penthouse) is shown in attached sketch no. 096. Use proper gasket rope
(min. 6mm diameter) in between all bolted flanges.
g. Do not apply any un-wanted external forces while fixing HV pipe to TR set –vebushing. Otherwise this would
result in failure of TR set’s – ve bushing and its stud.
h. To avoid malfunctioning of ESP operation due to mis-alignment of HV pipe in HV duct, always check & ensure
that HV pipe is at the center of HV duct.
i. Ensure the seal welding of HV duct with penthouse top roof. This weld joint should be checked for kerosene
test.
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High Voltage Assy. With T/R
Sketch No. 96
V. Erection & Alignment of Collecting Plate Rapping System
The erection of collecting plate rapping system should be started after completion collecting plate alignment and
erection of penthouse. Following sequence should be followed for erection of collecting plate-rapping system –
a. For this purpose refer attached typical sketches no. 097 to 102.
b. Fix the rapper studs on collecting plate top tad pole. Refer the sketch no. 100 showing its welding details and
sketch no. 097 for its location. Check and ensure that location of these stud’s centerline across the gas flow) is
at center of the adjacent top HV frame members.
c. Then fix the spreader bar and anvil beam on these studs, as shown in sketch no. 098 & 099 along with
reference drawing sent separately.
d. Take reference of the center of respective anvil beam and mark / transfer this center on inner roof and
penthouse top roof. Make opening of 90mm diameter w.r.t. these center points and position / install rapper
boot mounting assembly in line with center of respective anvil beam and then do the welding of boot
mounting assembly with both inner roof / penthouse roof. While welding rapper boot mounting, ensure that
all rapper boot mounting top flange are at same level. Before welding rapper boot mounting with inner /
penthouse roof following points should be ensured –
+Distance of rapper boot mounting flange to inner roof top surface as shown in attached sketch no. 097.
+Correct plumbness of rapper boot mounting assembly.
+Center of rapper boot mounting in line with the center of respective anvil beam and spirit level of anvil beam.
+Spirit level of rapper boot mounting top flange.
After ensuring above, seal welding of boot mounting with inner roof and penthouse top roof should be done.
This seal welding is to be checked for kerosene leak test and any defects / leakages found, it is to be rectified.
e. After completing alignment & welding of boot mounting assembly, fix the other parts of rapper i.e. rapper rod,
hypalon seal, rapper studs and then rapper coil with plunger, in sequence. While fixing rapper coil with
plunger, following check points are to be ensured –
+Hardened face of the plunger should be placed downwards (Follow the markings on rapper plunger).
+Verticality of rapper coil
+38mm projection of rapper plunger outside the rapper coil, as shown in sketch no. 102.
The above both checkpoints should be adjusted with the help of rapper studs. After correct alignment, tighten the
rapper studs and secure it firmly with help of checknuts.
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Collecting System Fit-Up Details
Sketch No. 100 Sketch No. 97
Sketch No. 99
Sketch No. 98
Similar procedure should be followed for all other rapper coils.
While erecting collecting plate rapper coils, ensure that all rapper coils are installed at same levels.
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Rigitrode System Fit-Up Details
Sketch No. 67
W. Erection & Alignment of Regitrode Rapping System
The erection of regitrode rapping system should be started after completion of support insulator alignment and
erection of penthouse.
Following sequence should be followed for erection of regitrode rapping system –
a. Fix the regitrode rapper rod clamp coupling on regitrode rapper rod.
b. Take reference of center of respective regitrode rapper rod clamp coupling and mark / transfer this centeron
penthouse top, so that rapper boot mounting position can be ensured.
c. After ensuring rapper rod clamp coupling center on penthouse top, cut a hole of 90mm diameter w.r.t. this
center point and position / install the rapper boot mounting assembly in line with center of respective rapper
rod clamp coupling and then do the welding of boot mounting assembly with penthouse roof. While welding
rapper boot mounting, ensure that all rapper boot mounting top flange are at same level.
Before welding the rapper boot mounting assembly following points to be ensured –
+Distance of rapper boot mounting flange to inner roof top surface as shown in attached sketch no. 067.
+Correct plumbness of rapper boot mounting assembly.
+Center of rapper boot mounting in line with center of respective anvil beam and spirit level of anvil beam.
+Spirit level of rapper boot mounting top flange.
After ensuring above, seal welding of boot mounting with penthouse top roof should be done. This seal welding is to
be checked for kerosene leak test and any defects / leakages found, it is to be rectified.
d. After completing alignment & welding of boot mounting assembly, fix the other components of regitrode
rapper systems like shaft insulator, hypalon seal, anvil cap, rapper studs & then rapper coil with plunger, in
sequence.
While fixing rapper coil with plunger, following points are to be ensured –
+Hardened face of plunger should be placed downwards (Follow the markings on rapper plunger).
+Verticality of rapper coil.
+38mm projection of rapper plunger outside the rapper coil as shown in schematic sketch no. 102.
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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Rigitrode System Fit-Up Details
Sketch No. 101
Sketch No. 102
X. Erection & Alignment of Inlet GD Rapping System
The erection of inlet GD rapping system should be started after completing erection and alignment of inlet nozzle
with GD screen.
Following sequence should be followed for erection of inlet GD screen rapping system –
a. For this purpose refer attached typical sketches no. 079 to 085, along with the reference drawing sent
separately.
b. After completing inlet GD screen alignment and its locking with nozzle side /bottom plates, fix the rapping
channel arrangement on GD screen, as per reference drawing. For reference, refer sketch no. 083 showing
typical view of rapping channel arrangement. Check and ensure that distances of this arrangement are
maintained as per reference drawing.
c. Then fix the single end tapered coupling /s on rapping channel arrangement, as per reference drawing. The
typical schematic sketch is attached with this as sketch no. 079.
d. Take reference of respective single end tapered coupling and transfer this center on nozzle top plate. Make a
suitable opening for inserting 80mm diameter rapper boot w.r.t. this center point and fix the rapper boot
mounting assembly in line with center of respective single end tapered coupling. While doing this maintain
spirit level of rapper boot flange. Once correct alignment of rapper boot is maintained, weld boot mounting
assembly with nozzle plate. Ensure that all rapper boot flanges are at same level.
Before welding rapper boot mounting with nozzle top plate, following points should be ensured –
+Distance of rapper boot mounting flange to single end tapered coupling as shown in referred drawing.
+Correct plumbness of rapper boot mounting assembly.
+Center of rapper boot mounting in line with the center of respective single end tapered coupling.
+Spirit level of rapper boot mounting top flange.
After ensuring above, seal welding of boot mounting with nozzle top plate should be done. This seal welding is to be
checked for kerosene leak test and any defects / leakages found, it is to be rectified.
e. After completing alignment & welding of boot mounting assembly, fix the other parts of rappers i.e. rapper rod
with rapper coupling , hypalon seal, rapper studs and then rapper coil with plunger, in sequence.
While fixing rapper coil with plunger, following check points are to be ensured–
+Hardened face of plunger should be placed downwards (Follow the markings on rapper plunger).
+Verticality of rapper coil
+38mm projection of rapper plunger outside the rapper coil as shown in sketch no. 102.
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Inlet & Outlet Nozzle Assy. Fit-Up
Sketch No. 79
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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Warning Sign Locations
Sketch No. 103
Y. Fixing of Warning Sign Boards and Mechanical Interlock System
+Warning Sign Boards
For safety precautions, warning signboards are to be fixed on all inspection doors and on TR sets. The typical
sketch of such warning signboard is attached with this as sketch no. 104. Also Thermax monogram to be fixed
at top of ESP, from where it is easily noticeable to others. Following are the location where warning signboards
are to be fixed. These locations are indicated in sketch no. 103.
Description Location
Warning Sign for Access Door
Warning Sign for Hopper Access Door
Warning Sign for Duct Access Door
Warning Sign for High Access Door
Thermax Monogram
Above Access Door
Above Access Door
Above Access Door
On TR Door
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.
The interlocking scheme is briefed as below, in detail.
For understanding purpose, following philosophy is explained for 3 Field ESP with 3 TR sets and 11 access doors.
The keys and locks shall have the letters engraved as per drawing shown below.
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+Operational Philosophy :For accessibility to ESP internals through access door, following sequence to be followed.
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DOOR INTERLOCK DIAGRAM
TRANSFER BLOCK - B1 & B2(KEY EXCHANGE ASSEMBLY)
TRANSFER BLOCK - C
TRANSFER BLOCK ‘A’ G3 G2 G1
X
XX2X1
X1 X2
B
B
B
B
B
B
B
B
BB
G3BW
G2BW
G1BW
D3BE
D2BE
D1BE
D3BW
D2BW
D1BW
TRCC3 TRCC2 TRCC1
5A ‘NO’ CONTACT
MOUNTING ON TRCC PANEL(LOCK FOR HT INTERLOCK)
GROUNDING SWITCHEARTH POSITION
LOCK ON GROUNDING SWITCH ENCLOSURE
DOOR INTERLOCKBOX MOUNTED INCONTROL ROOM
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 KEY3) 5A ‘NO’ CONTACT TO BE PROVIDED FOR D1, D2 & D3 SOCKET TO BE MOUNTED ON TRCC PANEL.
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.
Sl. No. Description TAG No. Total Qty.
1 Lock with 5A electrical contact (On TRCC) (Lock
with key & electrical switch) D1,D2,D3 3 nos.
2 Ground switch lock (For changing position &
interlock with TRCC on/off) (Lock without key)
1,D2,D3
3 nos.
3
Ground switch lock (For locking the grounding
switch to ESP earth position) (with key)
1,G2,G3
3 nos.
4
Transfer block assembly – A consists of 3 -nos.
lock without key & 1 no. master lock (`X’) with key
1,G2 ,G3 &
X
1 set.
5
Key exchange box (Transfer block assembly –C)
consist of 2 nos. lock with key (‘X1’,’X2’) & 1no.
master lock without key (‘X’)
1,X2 & X
1 set.
6
Key exchange box (Transfer block assembly –B1 & B2)
Consist of 7 nos. & 4 nos. access door locks
with key each & 1 no. master lock (`X1’ & ‘X2’
respectively) without key
1=7 nos.
B2=4 nos.
X1=1 no.
X2=1 no.
1 set.
7
Chain type door locks with out key for access (On ESP)
doors
11 Nos.
B
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WARNING
ALLOWABLE `CO' IN FLUE GAS = 1 % MAX.BE CAREFUL ABOUT EXPLOSIONS DUE TO `CO'.
CONTROL & TUNE YOUR EQUIPMENT OPERATION.
WHEN THE KILN IS STOPPED OR KEPT UNDER HOLD, ENSURE THAT THEESP 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.
THERMAX LIMITED
ENVIRO DIVISION, PUNE, INDIACUSTOMER SHOULD DISPLAY THE INSTRUCTIONS IN LOCAL LANGUAGE ALSO.
iklana baMd hao jaanaopr yaa kuC samaya tk raok idyao jaanaopr š.esa.pI.[nalaoT DOmpr 2imanaT mao baMd kroM [saI samaya e baI saI kOp Kulaa rKoM AaOr Aaya DI fOna
baMd kr doM [sa ko 5 imanaT turMt baad š.esa.pI.pja- eAr fOna baMd kroM
gaOsa mao kaba-na maaonaak\saašD kI inaQaa-irt maa~a AiQaktma 1 hO kaba-na maaonaak\saašD kI vajahsao haonaovaalao QamaakaoM ko ilae saavaQaanaI barite saBaI saMyaM~aMoko calana AcCI trhsao inayaMi~t AaOr saMtuilat rKoM
CO Explosion Warning Sign For Kiln
Sketch No. 105
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Installation & Commissioning ManualELECTROSTATIC PRECIPITATOR
HOOK SAFETY CHAIN.
KNOCK OVERHEAD DUST.
OPEN AND PADLOCK
ENSURE FAN IS STOPPED
PROVIDE ADEQUATELIGHT & VENTILATION
WARNING?EYE AND SKIN
PROTECTION
USE
HEAD AND NOSE
SEQUENCE, ENSURE THAT KEY INTERLOCKFOLLOW THE MECHANICAL KEY INTERLOCK
COMPONENTS BEFORE ENTRY.
AND EARTHING SWITCHES ARE GROUNDEDENSURE THAT TR SETS ARE SWITCHED OFF
DO NOT REMOVE HOOKS UNTIL WORK IS
ATTACH GROUNDING HOOKS ON ALL H.V.BEFORE ENTERING ANY H.V. AREA.
IS NOT TAMPERED.
HIGH VOLTAGE.
COMPLETED.
ACCESS DOOR
Typ. Warning Sign
Sketch No. 104
125
Installation & Commissioning Manual ELECTROSTATIC PRECIPITATOR
WARNING
WHEN THE BOILER IS STOPPED, ENSURE THAT THEI.D. FAN IS SWITCHED OFF AFTER 15 MIN. AND THEN
ESP PURGE AIR FAN SHOULD BE SWITCHED OFF AFTER 10 MIN.
ALLOWABLE `CO' IN FLUE GAS = 1 % MAX.BE CAREFUL ABOUT EXPLOSIONS DUE TO `CO'.
CONTROL & TUNE YOUR EQUIPMENT OPERATION.
THERMAX LIMITED
ENVIRO DIVISION, PUNE, INDIACUSTOMER SHOULD DISPLAY THE INSTRUCTIONS IN LOCAL LANGUAGE ALSO.
baayalar baMd hao jaanaopr 15 imanaT ko turMt baad Aaya DI fOna baMd krnaokI vyavasqaa kroM
]sako 10 imanaT turMt baad š.esa.pI. pja- eAr fOna baMd kroM
gaOsa mao kaba-na maaonaak\saašD kI inaQaa-irt maa~a AiQaktma 1 hO kaba-na maaonaak\saašD kI vajahsao haonaovaalao QamaakaoM ko ilae saavaQaanaI barite saBaI saMyaM~aMoko calana AcCI trhsao inayaMi~t AaOr saMtuilat rKoM
CO Explosion Warning Sign For Boiler
Sketch No. 106
Z. Air Leak Testing and Thermal Insulation Application Work
The air leak test is to be carried our to ensure proper sealing of ESP, as air leakages would affect not only ESP
performance, but can become a major cause of ESP and its internal damages.
The air leak testing is to be carried out after completion of all mechanical erection activities and before starting
thermal insulation application work.
Following is brief procedure to carry out the air leak test
a. Install ESPs purge air blower on ESP roof as per drawing and give the power supply to this blower (Temporary
power supply, with necessary precautions) also would serve the purpose).
b. Check & ensure the operation of blower i.e. direction of rotation / damper opening etc.
c. After completing all mechanical activities inside ESP (including fixing of all instruments like hopper level
indicators / thermostats / RTDs etc), especially welding work, box up the ESP by closing all access doors
(casing, hopper, nozzle, penthouse)
d. Provide the blanking at ESP inlet, at ESP outlet and at ESP hopper's outlet flange. The blanking at all these
locations should be done with seal welding.
e. Install a U-tube manometer (approx. 200mmWC) near accessible area of ESP either at penthouse access
door or at casing door.
f. Prepare soap water solution approx. 50 liter min. and a mug of approx. 250ml.
g. After completing the blanking and installing U-tube manometer, start the purge air blower.
h. Keep the purge air blower ON till U-tube manometer reaches to 90 to100 mmWC.
i. Once pressure reaches to above limit, pour soap water over all site weld joints. Especially all corner, site weld
joints are to be checked carefully.
j. While checking the welding leakages, do not allow pressure in U-tube manometer to reach beyond
125mmWC.
k. The bubble will be formed at the locations where weld leakage is present. Mark all such location and rectify
them by cleaning (grinding) & then again welding.
l. Repeat this procedure till no leakages are observed & then only completion of air leak test should be
decleared.
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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Installation & Commissioning ManualELECTROSTATIC PRECIPITATOR
127
Installation & Commissioning Manual ELECTROSTATIC PRECIPITATOR
D.U
.NO
.D
ES
CR
IPT
ION
Insulation Arrangement
Sketch No. 110-A
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Installation & Commissioning ManualELECTROSTATIC PRECIPITATOR
Insulation Arrangement
Sketch No. 110-B
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Installation & Commissioning Manual ELECTROSTATIC PRECIPITATOR
Insulation Arrangement
Sketch No. 110-C
Chapter 10
Electrical Activities
ELE
CTRO
STA
TIC
PREC
IPIT
ATO
R
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.
B. Fixing of Hopper Heaters with thermostat
i. Depending on type of application and type of hoppers, hopper heaters are provided for ESP hoppers.
ii. The hopper heaters should be fixed on hopper side walls, as shown in reference sketch. The sufficient cut outs
for hopper inspection door / hopper chute pipe / vibrator (as applicable) are provided on heaters.
iii. For fixing the hopper heaters, studs of M12 x 40Lg should be welded on hopper walls from outside, as shown
in reference drawing sent separately with attached sketch no. 118.
iv. After welding the studs, heaters can be fixed on hopper, as shown in reference drawing.
v. The connecting cables of hopper heaters should be routed through separate conduit, so that they can be
brought to respective JBs. While routing the cables through conduit, sufficient care should be taken to avoid
the damages to heater cables.
C. Fixing of Hopper Level Sensors with controller unit
i. Refer the typical sketch no. 115 for fixing the hopper level sensor with controller.
ii. The needed guidelines for fixing of the level controller with sensor are given in this sketch.
D. Fixing of Zero Speed Switch for RAVL (If applicable)
i. Refer the typical sketch no. 119 for fixing the ZSS.
ii. The needed guidelines for fixing ZSS are briefed in this sketch.
E. Fixing of Vibrators for Hopper (if applicable)
i. For fixing the hopper vibrators, refer the drawing sent separately.
F. Fixing of Purge Air Blower
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Installation & Commissioning Manual ELECTROSTATIC PRECIPITATOR
G. Fixing of RDP Panel
H. Placement of Auxiliary Control Panel in MCC room
I. Placement of TRCC & MTP Panels in control room
J. Fixing of JBs, as per Layout & Schedule
K. Fixing of LPBS for Purge Air & RAVL.
L. Fixing of RTDs in hopper (if applicable)
M. Fixing of RTDs in ESP inlet duct (if applicable)
N. Cable tray Laying / Cable Laying / Cable Termination / Cable Dressing of ESP
The interconnections between Control Panel & Transformer Rectifier Unit and between Control Panel & other
auxiliaries are indicated below.
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Installation & Commissioning ManualELECTROSTATIC PRECIPITATOR
ControlPanel(Representative)
TransformerRectifier Unit(Representative)
To Remote Alarm/Trip indication, HT On/Offindications (Optional)
To Remote On/Off
To Remote 4-20 mA indication
1
2
3
4
5
6
7
Refer following Sl. Nos. for above circled numberings, in detail.
Sl. No Cable Details Layout
Cable for Power Connections: PVC Insulated,
650 / 1100 V Grade, Aluminum Conductor,
Armoured cable. (Size & details as per Project
Rating)
Power cables should not to be mixed with any
control cable (Sr.No. 3, 4 & 5)
Cable for Primary Voltage Feedback : 2C or
3C2.5 sq. mm., PVC Insulated 650 / 1100 V
Grade, Copper Conductor, Armoured
Control Cable
Feedback cables should not to be mixed /
bunched with Cables for Secondary Current &
Voltage feedback & Cable for Alarm &
Annunciation, i.e. Cable No. 3 & 4. This can
be bunched with Power cable( Sr.No.1)
Cable for Secondary Current & Voltage
Feedback : 4C-1.5 sq. mm., PVC Insulated
650 / 1100 V Grade, Copper Conductor,
Overall shielded with minimum 80% shielding
Armoured Control Cable
These cables to be laid separately and not to
be mixed with power cables (Sr.No.1) or
Primary Voltage Feedback cable (Sr.No. 2) or
any other cable having potential higher than
30 V.
Cable for Alarm & Annunciation :
10C-2.5 sq. mm., PVC Insulated 650 / 1100
V Grade, Copper Conductor, Armoured
Control Cable
To be laid separately and not to be bunched
with Power Cable (Sr.No.1) or Primary Voltage
Feedback Cable (Sr.No.2) or Cable for
Secondary Current & Voltage (Sr.No. 3) or any
other cable having potential higher than 50 V
Cable for Remote On / Off (Optional) :
3C-1.5 or 2.5 sq. mm., PVC Insulated 650 /
1100 V Grade, Copper Conductor,
Armoured Control Cable
These cables should not to be mixed /
bunched with any power cable &
instrumentation cable.
Cable for Remote 4-20 mA Feedback
Indication (Optional) :
4C-1.5 sq. mm., PVC Insulated 650 / 1100 V
Grade, Copper Conductor, Overall shielded
with minimum 80% shielding Armoured
Control Cable.
These cables should not to be mixed /
bunched with any power cables / control
cable having potential higher than 30 V
Cable for Remote Alarm / Trip indication, HT
On / Off indications (Optional) *C-2.5 sq.
mm., PVC Insulated 650 / 1100 V Grade,
Copper Conductor, Armoured Control Cable
(* No. of cores as required, Pl. refer the project
specific schematic drawing)
Not to be mixed / bunched with any power
cable & instrumentation cable
1.
2.
3.
4.
5.
6.
7.
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Installation & Commissioning Manual ELECTROSTATIC PRECIPITATOR
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.
Q. Cable Shield Earthing
1. The shield earthing of the feedback cable depends upon the type of electromagnetic environment present at
site. If the surrounding environment consists of a low frequency (< 2MHz) electric field then the shield needs
to be grounded at the receiver end i.e. for feedback cable, it is at panel end.
If the surrounding environment consists of a high frequency (> 2MHz) electromagnetic field then the shield
shall be grounded at both the ends, i.e. for feedback cable it is at panel end & Transformer Rectifier end. This
will form a closed circuit to allow a high frequency noise to flow through the shield. To add effectiveness of
shielding for a selected band of frequencies, a capacitive coupled grounding shall be employed. The
capacitance value shall be selected based on the frequency band, common mode impedance of the cable &
the characteristic impedance of the cable.
2. While grounding the shield of the shielded cable, care shall be taken that the minimum length of the cable
remains unshielded (Typically 50 mm) This is illustrated in figure No. 2.
3. The extra cores of the cable, which are not required, shall be kept open and duly insulated at both the ends.
141
Installation & Commissioning ManualELECTROSTATIC PRECIPITATOR
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Installation & Commissioning Manual ELECTROSTATIC PRECIPITATOR
Figure 1
Power Cables:(Typically 415 V / 230 V)Control Panel SupplyFan Motors SupplyPump Motors Supply
Control Cables:(Typically 230 V 110 V)Relay SupplyContactor Supply
Signal Cables:(Typically 24 V / 4-20 mA,Instrumentation cable)Feedback CablesAlarm Cables
Metal Cable Tray
=30mm =100mm
Figure 2
Unshielded portion of shielded wire(Typically 50mm)
Unused core of cable shall bekept opened & insulated
Shielded Wire
≥300 mm
R. Earthing of ESP and electrical components / panels
The ESPs earthing is very important from ESP's functional point of view. Also functioning of ESPs electrical items like
rapper coils, Purge Air Blower, RAVL etc. Hence earthing of ESP and all other components are very much critical and
earthing of these components must be ensured prior to its commissioning.
Following are few guidelines for earthing of ESP
i. The separate earthing should be provided for ESP earthing grid and ESP control room.
ii. The ESP earth grid and ESP control room earthing should be independent.
iii. Also ESP earthing grid and ESP control room earthing must be independent from plant earthing. No p l a n t
machinery should be connected with ESP / ESP control room earthing.
iv. For ESP earthing, four (4) separate earthing pits must be provided preferably at four (4) corners of ESP. All
these four (4) earth pits must be interconnected and ESP earth grid must be connected to earth pits at least at
two (2) separate earth pits. Earth pits shall be with 'B' class GI pipe of 50-mm diameter ID and 3 meter long as
per IS-3043.
v. ESPs main earthing grid connecting to earth pits as well as ESP control room shall be of two runs of 50mm x
6mm thk GI strips. These strips shall be run along the cable trays, wherever possible.
vi. The two nos. GI. strips of 50mm x 6mm thk. should be taken along the diagonally opposite ESP columns &
shall be connected to the earth grid on the roof.
vii. All hoppers are to be connected to earth grid by 25mm x 3mm thk GI strips.
viii. All panels must be connected to main earth grid by 50mm x 6mm thk GI strips at two separate points.
ix. All electrical items like purge air blower, transformer rectifier sets, RAVL motor, rapper coils etc. must have two
separate earthing connections, as per IS 3043
x. For earthing of ESP's electrical components, correct size earthing strips / wires should be used, as specified in
the earthing layout drawing / below mentioned table.
123456789
1011121314151617
Equipment
T/R SetEarth Grid (along ESP Column)Earth Grid (On ESP Roof)
TRCC PanelAuxiliary Control PanelMicro Tapper Panel
Earth SwitchHoppersGrid for Upper / Lower Platform & at Hopper Level PlatformRapper Distribution Panel
Insulator Heater JBLevel Controller JBHopper Heater JB
Control Junction BoxesRapper CoilsPurge Air BlowerRotary Air Lock Valve
50 x 6 MM. STRIP50 x 6 MM. STRIP50 x 6 MM. STRIP50 x 6 MM. STRIP50 x 6 MM. STRIP50 x 6 MM. STRIP50 x 6 MM. STRIP25 x 3 MM. STRIP25 x 3 MM. STRIP25 x 3 MM. STRIP2 X 8 SWG WIRE2 X 8 SWG WIRE2 X 8 SWG WIRE2 X 8 SWG WIRE2 X 8 SWG WIRE2 X 8 SWG WIRE2 X 8 SWG WIRE
Sl. No. GI Strip / Wire Size
143
Installation & Commissioning ManualELECTROSTATIC PRECIPITATOR
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.
144
Installation & Commissioning Manual ELECTROSTATIC PRECIPITATOR
145
Installation & Commissioning ManualELECTROSTATIC PRECIPITATOR
Earthing Arrangement of Control Panel And TR Set For ESP
Sketch No. 113
146
Installation & Commissioning Manual ELECTROSTATIC PRECIPITATOR
Hook-Up For Insulator Heater
Sketch No. 114
147
Installation & Commissioning ManualELECTROSTATIC PRECIPITATOR
Hook-Up For Level Switch
Sketch No. 115
148
Installation & Commissioning Manual ELECTROSTATIC PRECIPITATOR
Hook-Up For Temp. Element
Sketch No. 116
149
Installation & Commissioning ManualELECTROSTATIC PRECIPITATOR
Sketch No. 117
Hook-Up For Temp. Element
150
Installation & Commissioning Manual ELECTROSTATIC PRECIPITATOR
Hook-Up For Thermostat
Sketch No. 118
151
Installation & Commissioning ManualELECTROSTATIC PRECIPITATOR
Hook-Up For Zero Speed Switch
Sketch No. 119
Chapter 11
ESP Pre CommissioningChecklists
ELE
CTRO
STA
TIC
PREC
IPIT
ATO
R
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
Installation & Commissioning Manual ELECTROSTATIC PRECIPITATOR
153
Installation & Commissioning ManualELECTROSTATIC PRECIPITATORESP's M
ech
anic
al C
om
ple
tion C
heck
Lis
ts
Nam
e o
f C
ust
om
er:
Pla
nt
/ Site L
oca
tion:
Cust
om
er
PO
No.:
Therm
ax
OC
No.:
Nam
e o
f Therm
ax
Repre
senta
tive
:
Sl.
No.
Check
Poin
t D
esc
ription
Com
ple
tion D
ate
Fie
ld 1
Fie
ld 2
Civ
il F
oundation
ESP
foundatio
n insp
ectio
n a
nd its
acc
epta
nce
pro
toco
l (a
xial &
dia
gonal m
easu
rem
ents
as
per
dra
win
g).
1
ESP S
upport
Str
uct
ure
ESP s
upport s
truct
ure
ere
ctio
n a
s per
dra
win
g a
nd its
alig
nm
ent (i.e
. plu
mb,
axi
al &
dia
gonal m
easu
rem
ents
) its
acc
epta
nce
pro
toco
l.
ESP B
EA
RIN
G
Bearing a
lignm
ent in
spect
ion p
roto
col [leve
l (s
pirit
& w
ate
r),
axi
al &
dia
gonal m
easu
rem
ents
w.r.t.
fixed b
earing a
s per
bearing layo
ut dra
win
g] and its
acc
epta
nce
pro
toco
l.
1 1
Casi
ng
Ere
ctio
n o
f ESP c
asi
ng p
anel &
colu
mn,
top &
bottom
girder
as
per
dra
win
g w
.r.t.
ESP c
ente
rlin
e a
nd its
insp
ect
ion
pro
toco
l (for
plu
mb,
axi
al &
dia
gonal m
easu
rem
ents
).1 2 3
Insp
ect
ion o
f w
eld
join
ts.
Kero
sene leak
test
of all
weld
join
ts..
All
weld
join
ts s
hould
be fre
e fro
m for
left o
ut w
eld
ing /
weld
ing d
efe
cts
like b
low
hole
s, w
eld
ing c
rack
s etc
.
Rem
ova
l all
tem
pora
ry s
upports
pro
vided for
casi
ng e
rect
ion /
weld
ing p
urp
ose
, after
ESP a
lignm
ent and b
efo
re E
SP b
ox
up.
Inle
t N
ozz
le w
ith P
erf
ora
ted S
heets
Insp
ectio
n o
f in
let nozz
le a
ssem
bly
& its
inst
alla
tion w
ith p
erfo
rate
d s
hee
ts a
s per
dra
win
g.
Insp
ectio
n o
f w
eld join
ts.
Ker
ose
ne
leak
test
of all
wel
d join
ts..
All
wel
d join
ts s
hould
be
free
fro
m for
left o
ut w
eldin
g /
wel
din
g d
efec
ts lik
e blo
w h
ole
s, w
eldin
g c
rack
s et
c.
Alig
nm
ent of in
let nozz
le inle
t fla
nge
(plu
mbnes
s and d
iagonal).
Outlet
Nozz
le w
ith P
erf
ora
ted S
heets
Insp
ectio
n o
f outle
t nozz
le a
ssem
bly
& its
inst
alla
tion w
ith p
erfo
rate
d s
hee
ts a
s per
dra
win
g.
Insp
ectio
n o
f w
eld join
ts.
Ker
ose
ne
leak
test
of all
wel
d join
ts..
All
wel
d join
ts s
hould
be
free
fro
m for
left o
ut w
eldin
g /
wel
din
g d
efec
ts lik
e blo
w h
ole
s, w
eldin
g c
rack
s et
c.
1 2 3 1 2 3A
lignm
ent of outle
t nozz
le inle
t fla
nge
(plu
mbnes
s and d
iagonal).
Check
ed &
Witness
ed
by
Fie
ld 3
TH
ERM
AX
Cust
om
er
154
Installation & Commissioning Manual ELECTROSTATIC PRECIPITATORSl.
No.
Check
Poin
t D
esc
ription
Com
ple
tion D
ate
Fie
ld 1
Fie
ld 2
Hopper
with its
baff
le p
late
s and o
ther
acc
ess
ori
es
Ere
ctio
n o
f hopper
as
per
dra
win
g w
ith h
opper
baffle
pla
tes
and insp
ect
ion d
oor.
Insp
ect
ion o
f hopper
outlet flange/s
for
its
spirit /
wate
r le
vel.
Inst
alla
tion o
f hopper
heate
r th
erm
ost
at (a
s per
dra
win
g), if applic
able
.
Inst
alla
tion o
f hopper
heating p
ad,
(as
per
dra
win
g), if applic
able
.
Inst
alla
tion o
f Rota
ry A
ir L
ock
Valv
e a
nd S
lide G
ate
belo
w h
opper
(as
per
dra
win
g), if applic
able
. C
heck
the fla
nge to
flange s
ealin
g.
Collect
ing P
late
Ass
em
bly
Check
all
colle
ctin
g p
late
s are
fre
e fro
m b
ow
s /
loca
l defo
rmatio
ns.
Insp
ectio
n o
f co
llect
ing p
late
ass
emblie
s fo
r its
dia
gonals
and o
ther
mea
sure
men
t, a
s per
dra
win
g.
Check
the tig
htn
ess
of fa
steners
use
d for
colle
ctin
g p
late
s ass
em
blie
s and its
weld
ing b
efo
re c
olle
ctin
g p
late
ere
ctio
n.
Weld
ing o
f all
fast
eners
(N
ut to
bolt
weld
ing) use
d for
colle
ctin
g p
late
s /
its a
ssem
blie
s after
alig
nm
ent.
Insp
ectio
n of to
p H
V fra
me
erec
tion
and
its
alig
nmen
t (le
vel &
posi
tioni
ng w
.r.t. a
dja
cent
colle
ctin
g p
late
row
s).
Ensu
re tha
tth
e re
gitr
ode
row
s (in
gas
flow
direc
tion)
are
in the
mid
-way
of th
e adja
cent
colle
ctin
g p
late
row
s.
Check
ed &
Witness
ed b
y
Fie
ld 3
TH
ERM
AX
Insp
ect
ion o
f w
eld
join
ts.
Kero
sene leak
test
of all
weld
join
ts..
All
weld
join
ts s
hould
be fre
e fro
m for
left o
ut w
eld
ing /
weld
ing d
efe
cts
like b
low
hole
s, w
eld
ing c
rack
s etc
.
Inst
alla
tion o
f hopper
leve
l pro
be a
s per
dra
win
g.
Inst
alla
tion o
f hopper
vibra
tors
(as
per
dra
win
g), if applic
able
.
Insp
ect
ion o
f flo
atin
g c
hannel arr
angem
ent fo
r axi
al, d
iagonal m
easu
rem
ents
and w
ate
r le
vel.
Check
the s
traig
htn
ess
& p
lum
b o
f in
stalle
d c
olle
ctin
g p
late
, in
its
fre
e h
angin
g c
onditi
on.
All
colle
ctin
g p
late
s sh
ould
be
stra
ight in
the tole
rance
of +
/- 5
mm
, eith
er
side.
Regitro
des
with its
allie
d p
art
s
Che
ck the
straig
htne
ss o
f all
inst
alle
d r
egitr
odes
, in
its
free
hang
ing c
ond
ition.
All
regitr
odes
mus
t be
stra
ight
.
Che
ck the
gap b
etw
een
colle
ctin
g p
late
and
reg
itrode,
usi
ng G
O /
NO
GO
typ
e gaug
e. A
ll te
mpora
ry lo
ckin
g /
sup
ports
of
regitr
ode
fram
e m
ust be
rem
ove
d b
efore
gap c
heck
ing.
Whi
le c
heck
ing the
gap,
top H
V fra
me
shoul
d b
e in
fre
e ha
ngin
gco
nditi
on.
Rec
ord
all
the
dev
iatio
ns o
f th
is in
spec
tion
and
atta
ch the
rec
ord
s w
ith thi
s ch
eckl
ist.
Weld
ing o
f all
fast
eners
(N
ut to
bolt
weld
ing) use
d for
regitr
odes
and its
alli
ed p
arts,
after
gap c
heck
ing.
ESP B
aff
le P
late
s
Check
inst
alla
tion o
f ca
sing b
affle
pla
tes
as
per
dra
win
g.
All
baffle
pla
te s
hall
be s
eal w
eld
ed w
ith c
asi
ng p
anel. N
o g
ap b
etw
een b
affle
pla
te a
nd c
asi
ng s
ide p
anel is
allo
wed.
Support
Insu
lato
r
Inst
alla
tion o
f su
pport insu
lato
r in
stalla
tion a
nd its
alli
ed p
arts.
Alig
nm
ent of to
p H
V fra
me,
after
support insu
lato
r lo
adin
g.
Collect
ing P
late
Rappin
g S
yste
mA
lignm
ent (v
ertic
alit
y /
plu
mb) of ra
pper
rods.
1 3 5 7 8 1 3 4 6 12 4 6 2 5 2 3 4 1 2 1 2 1
Cust
om
er
Installation & Commissioning ManualELECTROSTATIC PRECIPITATOR
3 52 4
Exp
osu
re o
f ra
pper
plu
nger
outs
ide the r
apper
coil.
The p
lunger
should
be p
roje
cted 3
8m
m (O
NLY
)
outs
ide the c
oil,
for
effect
ive r
appin
g.
Gro
undin
g o
f th
e r
apper
rods.
Alig
nm
ent of ra
pper
coils
. A
ll ra
pper
coils
must
be in c
orr
ect
vertic
al posi
tion (plu
mb).
Sealin
g o
f ra
pper
rods,
usi
ng h
ypalo
n b
oot and c
lam
ps.
Check
Poin
t D
esc
ription
Sl.
No.
Dis
charg
e E
lect
rode R
appin
g S
yste
m
1 2G
roundin
g o
f th
e r
apper
rods.
Alig
nm
ent (v
ertic
alit
y /
plu
mb) of re
gitr
ode r
apper
rod a
nd s
haft insu
lato
rs.
3Exp
osu
re o
f ra
pper
plu
nger
outs
ide the r
apper
coil.
The p
lunger
should
be p
roje
cted 3
8m
m
(O
NLY
) outs
ide the c
oil,
for
effect
ive r
appin
g.
Sealin
g o
f ra
pper
rods,
usi
ng h
ypalo
n b
oot and c
lam
ps.
Leve
l of ra
pper
coils
. A
ll ra
pper
coils
must
be in c
orr
ect
vertic
al posi
tion (plu
mb).
54
Inle
t G
as
Dis
trib
ution S
creen R
appin
g S
yste
m
Alig
nm
ent (v
ertic
alit
y /
plu
mb) of ra
pper
rods
and d
ouble
taper
ed r
apper
rods.
Exp
osu
re o
f ra
pper
plu
nger
outs
ide the r
apper
coil.
The p
lunger
should
be p
roje
cted 3
8m
m (O
NLY
)
outs
ide the c
oil,
for
effect
ive r
appin
g.
Sealin
g o
f ra
pper
rods,
usi
ng h
ypalo
n b
oot and c
lam
ps.
1.
2. 54G
roundin
g o
f th
e ra
pper
rods.
1C
heck
corr
ect in
terlock
s are
fix
ed o
n fo
llow
ing lo
catio
ns -
Mech
anic
al In
terl
ock
Sys
tem
s
a.
TR s
et (G
roun
din
g S
witc
h &
Liv
e Po
sitio
n Sw
itch)
.
f. Inle
t &
Outle
t N
ozz
le A
ccess
Doors
.
b.
TRC
C P
ane
l.
c. C
asi
ng A
cces
s D
oors
.
d.
Hopper
Acc
ess
Doors
.
e. P
enth
ous
e A
cces
s D
oors
.
Check
Funct
ionin
g o
f in
terlock
sys
tem
with
indiv
idual ke
ys &
tra
nsf
er
blo
cks.
2
Penth
ouse
with insu
lation
Inst
alla
tion o
f penth
ouse
panels
as
per
dra
win
g a
nd its
seal w
eld
ing.
Kero
sene leak
test
of all
seal w
eld
join
ts.
Therm
al in
sula
tion o
f penth
ouse
top p
late
insu
latio
n fro
m insi
de.
The therm
al in
sula
tion s
hould
not to
uch
to the s
haft insu
lato
r. P
roper
cutti
ng to b
e e
nsu
red a
round the s
haft insu
lato
r.
Com
ple
tion D
ate
Fie
ld 1
Fie
ld 2
Check
ed &
Witness
ed b
y
Fie
ld 3
TH
ERM
AX
1 2 3
Cust
om
er
155
156
Installation & Commissioning Manual ELECTROSTATIC PRECIPITATOR
1 2
Purg
e A
ir S
yste
m
Fix
ing o
f anti v
ibra
tion p
ads
and fle
xible
connect
ion(a
t in
let &
outlet of blo
wer)
for
purg
e a
ir b
low
er.
Check
the loca
tion o
f purg
e a
ir s
yste
m,
as
per
dra
win
g.
While
inst
alli
ng the p
urg
e a
ir s
yste
m,
ensu
re that
there
is
suffic
ient sp
ace
ava
ilable
aro
und the filt
er
unit
/ blo
wer
/ ele
ctric
moto
r, for
main
tenance
purp
ose
.
Monora
il S
truct
ure
with lifting e
quip
.
Check
Poin
t D
esc
ription
Sl.
No.
1
2W
eld
ing o
f st
oppers
at both
fre
e e
nds
of th
e m
onora
il beam
.
Monora
il in
stalla
tion,
alig
nm
ent and w
eld
ing a
s per
dra
win
g
3In
stalla
tion o
f lif
ting e
quip
ment (C
hain
Pulle
y Blo
ck) w
ith tro
lley.
Transf
orm
er
Rect
ifie
r Set
with H
V D
uct
Free tra
vel of th
e tro
lley
with
chain
blo
ck.
14
Ere
ctio
n o
f TR
set
and its
HV d
uct
ing a
s per
dra
win
g.
Oil
leve
l in
the T
R s
et.
2. 4O
per
atio
n o
f TR
set
earthin
g s
witc
h.
Com
ple
tion D
ate
Fie
ld 1
Fie
ld 2
Fie
ld 3
1
Chec
k th
e TR
set
oil
BD
V v
alu
e. If BD
V v
alu
e is
les
s th
an 5
0 k
V, the
TR o
il re
-filt
ratio
n is
to b
e bone,
till
BD
V v
alu
e re
ach
es m
ore
than 5
0 k
V. T
his
is
to b
e done
bef
ore
TR s
et is
erec
ted o
n E
SP top.
3
Check
ed &
Witness
ed b
y
TH
ERM
AX
Cust
om
er
Chapter 12
Pre CommissioningActivities
ELE
CTRO
STA
TIC
PREC
IPIT
ATO
R
Following are the pre commissioning activities, to be carried out in the sequence / parallel mentioned below.
Pre Commissioning Activities
+Checking of cable continuity
/megger for all power / control /
feedback cables
+Gas Distribution Test +
value.
Checking of TR set oil BDV
+Checking of earth resistance +
per drawing
Checking of TR panel wiring, as +
heaters w.r.t. Thermostat setting
Operational checking of hopper
+
(Resistance / Continuity checking)
as per designed groups.
Check ing o f RDP pane l +
load
Checking of TR panelfor lamp +
Insulator heaters w.r.t. Thermostat
setting
Operat ional check ing of
+
lamp load testing
Checking of MTP panel and its +
Circuit & Short Circuit test
Checking of TR set for Open +
calibration of hopper level
controllers / Hopper Vibrators (if
applicable)
Ope ra t i ona l check i ng /
+
rappers and rapper lift checking
Checking of MTP panel with all +Air load test +
Air Blower
Operational checking of Purge
+Removal of Structural Bearing locking
The approx. time required for pre-commissioning is 7 days.
Some of the above precommissioning activities are briefed below
I. Gas Distribution Test
For efficient & desirable operational performance of ESP, gas flow needs to be uniform across the cross section of
ESP. To check the gas flow pattern inside ESP, gas distribution (GD) test is to be carried out as briefed below.
+For GD test, the velocity readings are to be taken in each gas passage of ESP with the help of anemometer.
+The velocity readings are to be taken at approximately each 1m height in each gas passage.
+The 500mm of top & bottom portion top of gas passage can be skipped, as velocity readings might be
disturbed in this zone.
+Always velocity readings are to be taken at outlet side of first field.
+The velocity readings should be taken and noted in the prescribed tabular format. The attached format can be
referred.
+After conducting the GD test,velocity readings shall be compiled and analysed w.r.t. average velocity.
To correct the gas flow pattern, the diverter plates and / or perforated plate hole blocking is to be done. To
achieve correct gas distribution, the test might be required to be done several times.
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Installation & Commissioning Manual ELECTROSTATIC PRECIPITATOR
158
Installation & Commissioning ManualELECTROSTATIC PRECIPITATOR
Gas
Pass
ag
e
Appro
x. H
eig
ht
from
bott
om
8.5
m7
.5 m
5.5
m4
.5 m
3.5
m2
.5m
1.5
m
0.5
m
Nos.
In %
Nos.
In %
Rem
ark
s:
1 2 3
PREC
OM
MIS
SIO
NIN
G R
EPO
RT (
ESP)
Gas
Dis
trib
ution R
eport
Form
at
Form
at: T
-EPD
-SR-F
-02
3
Cust
om
er:
Pla
nt
Loca
tion:
Date
: Tim
e:
From
Hrs
To
H
rs
Inspection Door Side
12
39
10
11
45
67
16
17
18
AV
ERA
GE V
ELO
CIT
Y (
V a
vg)
m/s
ec
12
13
14
15
8
1.1
5 t
imes
V a
vgm
/sec
1.4
0 t
imes
V a
vgm
/sec
Tota
l Velo
city
Readin
gs
Nos.
No. of
readin
gs
within
1.1
5 t
imes
V a
vg
No. of
readin
gs
within
1.4
0 t
imes
V a
vg
1.
Indic
ate
the
casi
ng insp
ectio
n d
oor
side
in the
report.
2.
The
gas
dis
trib
utio
n tes
t is
conduct
ed a
t fie
ld 1
outle
t si
de.
3.
The
ID fan c
urr
ent, d
am
per
posi
tionin
g a
nd F
an S
pee
d is
to b
e note
d in the
report.
For
Therm
ax
Ltd
For
Cust
om
er
Note
s: During tes
t -
The
ID F
an c
urr
ent w
as
A
mps
and ID
fan inle
t dam
per
open
ing w
as
%
During tes
t -
The
FD
Fan c
urr
ent w
as
A
mps
and F
D fan inle
t dam
per
open
ing w
as
%
The
above
form
at is
for
18
gas
pass
age
with
9m
colle
ctin
g p
late
hei
ght. S
imila
r fo
rmat sh
ould
be
modifi
ed for
more
num
ber
of gas
pass
age
and for
hig
her
colle
ctin
g
pla
tes.
EN
VIR
O D
IVIS
ION
TH
ERM
AX L
TD
EN
VIR
O D
IVIS
ION
TH
ERM
AX L
TD
6.5
m
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.
159
Installation & Commissioning Manual ELECTROSTATIC PRECIPITATOR
V. Checking of TR set oil BDV value.
Several times Transformer Rectifier sets are stored for longer period i.e. for more than six months, at sites. Under
such circumstances, TR set oil needs to be checked for its BDV value. To check the TR set oil BDV value, following
steps are to be followed.
a. Take oil container (normally made from stainless steel) of 1liter capacity to collect the oil samples from TR set.
For this purpose, if steel oil containers are not available, amber coloured glass bottle can be used. The oil
container must be air tight, so that atmospheric air should not be entered in bottle, after oil sample is collected
in the container. PLEASE NOTE THAT, PLASTIC BOTTLES SHOULD NOT BE USED FOR TAKING THE
OIL SAMPLES.
b. First clean the lower oil-tapping valve located on TR set bottom side. Remove the entire dirt / burrs from this
valve and then open the dummy plug from valve.
c. Collect approx. 250ml of oil from TR set in container and rinse container with this oil. Once again clean the
oil-tapping valve opening, with this oil. Repeat this procedure for 2 to 3 times more, so that the oil container /
bottle is thoroughly cleaned with the TR set oil.
d. Then collect the oil sample in cleaned oil container. While collecting oil sample, do not allow any air bubble
in the oil filled container.
e. Once the oil container is full of oil, seal the container in such a way that no air can enter inside the container.
f. Clean / rinse the BDV tester kit 2-3 times, with the oil, of which BDV testing is to be done.
g. Then check the oil BDV value using BDV tester kit.
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.
VI. Checking of TR panel wiring & TR panel for lamp load
+This it to be done to check the healthiness of TR panel and TR controller.
VII. Checking of TR set
+The TR set should be checked for its Meger test, Open Circuit Test and Short Circuit Test. This is to be done to
ensure the healthiness of TR set.
VIII. Air load test
+The air load is to be done to check healthiness of ESP fields.
+Air load test is to be done after completing ESP's all inside activities.
The formats of the precommissioning reports are attached herewith.
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Installation & Commissioning ManualELECTROSTATIC PRECIPITATOR
161
Installation & Commissioning Manual ELECTROSTATIC PRECIPITATOR
PRECOMMISSIONING REPORT
Page 1of 7
Application:-Client:-Client’s PO No.:- Thermax’s OC No:-
Format: T-EPD-SR-F-023 Rev.: 1
T/R SETS & TRCC DETAILS
Make Serial No.Field No.
TR Set TRCC TR Set TRCC ControllerRemark
Field 1
Field 2
Field 3
T/R SETS: MEGGER AND OIL DIELECTRIC STRENGTH TEST
TR SET MEGGER TEST RESULTS
1. Remove all bushing external connections. Short the primary side bushings and secondary sidebushings 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
50
500
100
Date:Name:Sign:COMPANY: THERMAX CUSTOMER CONSULTANT
DESCRIPTION FIELD 1REQUIRED (IN M )O FIELD 2 FIELD 3
Primary To Earth (LT To Earth)
Primary To Secondary (LT To HT)
Secondary To Earth ( HT To Earth)
TRANSFORMER OIL B.D.V. TEST RESULT
Note: Gap between electrodes = 2.5 mm and Minimum Required B.D.V = 50 kV (For mineral base oil) Ambient Temp: - º C
FIELD 1 FIELD 2 FIELD 3Average
162
Installation & Commissioning ManualELECTROSTATIC PRECIPITATOR
PRECOMMISSIONING REPORT
Page 2of 7
T/R PANELS LAMP LOAD TEST
1. Check all TR Panel connections as per drawing.2. Remove the TR Panel outgoing cables that goes to TR set.3. Connect two 230V / 100W bulbs in series, across the TR Panel outgoing terminals.4. For lamp load test, the IS setting to be kept at mA.5. Check the TR controller for soft start function. During this soft start, primary voltage
should increase gradually.6. After lamp load test, check all interlocks / alarms, by simulating the fault conditions.
LAMP LOAD TEST RESULTS
Field 1 Field 2 Field 3Test 1Test 2Remarks Controller Healthy /
Not HealthyController Healthy / Not
HealthyController Healthy / Not
Healthy
Note:- For healthy lamp load test, both the lamps should glow steadily.
Application:-Client:-Client’s PO No.:- Thermax’s OC No:-
Date:Name:Sign:COMPANY: THERMAX CUSTOMER CONSULTANT
163
Installation & Commissioning Manual ELECTROSTATIC PRECIPITATOR
Page 3of 7
T/R SETS: OPEN CIRCUIT TEST
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.
OPEN CIRCUIT TEST RESULTS
Field No. PrimaryVoltage (V)
PrimaryCurrent (A)
SecondaryVoltage (kV)
Sec. CurrentSet Pt. (mA)
Remarks
Field 1
Field 2
Field 3
Note: - For healthy TR set, Primary Current values should not exceed 6 amps for ratings upto 500mAand 10 Amps for ratings upto 1500mA.In case of excess primary current, the TR sets should be switched off and TR sets are to bechecked for abnormalities.
T/R SETS: SHORT CIRCUIT TEST
1. Connect the TR set HT bushing to Earth either by connecting a separate wire or by operatinggrounding 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%.
SHORT CIRCUIT TEST RESULTS
Pass & FieldNo.
Sec. Current(Is) set Point
PrimaryVoltage (V)
PrimaryCurrent (A)
SecondaryVoltage (kV)
SecondaryCurrent (mA)
Remarks
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
PRECOMMISSIONING REPORT
Application:-Client:-Client’s PO No.:- Thermax’s OC No:-
Date:Name:Sign:COMPANY: THERMAX CUSTOMER CONSULTANT
164
Installation & Commissioning ManualELECTROSTATIC PRECIPITATOR
Page 4of 7
TESTING OF EARTHING STATIONS
EarthStation No.
Earth Resistance (In m )O
12345678910
Earth Resistance of Grid = O
Note : Earth grid resistance should be less than 1 O
MEGGER TEST OF FIELD
This test should be carried out by megger of 5kV
Bus Section No. Insulation Level (M )O12345678910
PRECOMMISSIONING REPORT
Application:-Client:-Client’s PO No.:- Thermax’s OC No:-
Date:Name:Sign:COMPANY: THERMAX CUSTOMER CONSULTANT
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Installation & Commissioning Manual ELECTROSTATIC PRECIPITATOR
Page 5of 7
T/R SETS: AIR LOAD TEST
This test is to be carried out through TRCC panel only.
Field 1 Field 2P rimary Secondary P rimary Secondary
MASet
Point Voltage(V)
Current(A)
Voltage(kV)
Current(mA)
SparkRate Voltage
(V)Current
(A)Voltage
(kV)Current
(mA)
SparkRate
Field 3P rimary Secondary
MASet
Point Voltage(V)
Current(A)
Voltage(kV)
Current(mA)
SparkRate
PRECOMMISSIONING REPORT
Application:-Client:-Client’s PO No.:- Thermax’s OC No:-
Date:Name:Sign:COMPANY: THERMAX CUSTOMER CONSULTANT
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Installation & Commissioning ManualELECTROSTATIC PRECIPITATOR
Page 6of 7
RAPPING SYSTEM - ELECTRICAL TEST REPORT
Micro–Tapper Panel Sl. No.: Matrix Size :
TEST RESULTS
RapperNo.
GroupNo.
Rapperfor CE /
EE /PDPL
ForwardMeggaring
+ve to Row /-ve to Col.
ReverseMeggaring+ve to Col-ve to Row
Row toEarth
Col.to
Earth
LiftSetting(Inches)
ActualLift
(Inches)
Remarks
1234567891011121314151617181920212223242526272829303132
PRECOMMISSIONING REPORT
Application:-Client:-Client’s PO No.:- Thermax’s OC No:-
Date:Name:Sign:COMPANY: THERMAX CUSTOMER CONSULTANT
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Installation & Commissioning Manual ELECTROSTATIC PRECIPITATOR
Page 7of 7
RapperNo.
GroupNo.
Rapperfor CE /
EE /PDPL
ForwardMeggaring
+ve to Row /-ve to Col.
ReverseMeggaring+ve to Col-ve to Row
Row toEarth
Col.to
Earth
LiftSetting(Inches)
ActualLift
(Inches)
Remarks
3334353637383940414243444546474849505152535455565758596061626364
PRECOMMISSIONING REPORT
Application:-Client:-Client’s PO No.:- Thermax’s OC No:-
Date:Name:Sign:COMPANY: THERMAX CUSTOMER CONSULTANT
Chapter 13
Commissioning Activities
ELE
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Following is the sequence for commissioning.
1. Prior to ESP commissioning all pre commissioning and thermal insulation application works must be
completed in all respect. The respective reports should be signed off.
2. Switch ON hopper and support insulator heaters min. 4 hrs prior to plant start up.
3. Switch ON rapping system min. 4 hrs. prior to ESP charging.
4. Switch ON purge air blower, dust-conveying system below ESP hoppers min. 4 hrs. prior to ESP charging.
5. Check the healthiness of hopper level sensors / controllers.
6. Charge the TR sets one by one. The TR sets should be charges only when the designed operating temperature
is reached and is steady for minimum 2 hours of operation. Fine-tuning of TR sets to be done from last field TR
set. Set the parameters for steady mA setting with minimum spark. Maximum allowable sparks per minute is
10 sparks per minute.
7. For last field, NO SPARKS SHOULD BE ALLOWED.
ESP
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Page 1of 3
Format: T-EPD-SR-F-025 Rev.: 1
COMMISSIONING REPORT
1. Product : ELECTROSTATIC PRECIPITATOR
2. 2.a ) Clients name and Location :
2.b) Client’s PO No. & date :
2.c) Thermax O.C. No. :
3. Application :
4. ESP Model :
5. Fuel used :
6. ESP Parameters
Inlet OutletParameters UoMDes ign Actual Des ign Actual
Gas Flow AM3 / Hr
Inlet Dust load gm / NM3 NA NA
Out let Dustconcentration
mg / NM3 NA NA
Temperature °C
7. Load on customer’s equipment :
against rated load
8. TR set Operational Readings :
Primary S ide Secondary SideField No.
Voltage inVolts
Current in amps Voltage in kV Current in mA
Sparksper min.
Field 1
Field 2
Field 3
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Installation & Commissioning Manual ELECTROSTATIC PRECIPITATOR
9. Microtapper Panel :
i) Make and Sl. No.ii) Modeliii) Parameter Setting
GroupNo.
01 02 03 04 05 06 07 08 09 10 11 12
RTT inmin.
Lift ininch.
10. Dust Handling System (Below Hopper) :
A. Scope : Thermax / CustomerB. Pneumatic Conveying System :
i) Make and Modelii) Performance
C. Screw Conveyor :
i) Make and Model ii) Drive make and Model iii) Performanceiv) Current Drawn in amps
D. Rotary Airlock Valve :
i) Make and Modelii) Drive make and modeliii) Performanceiv) Current Drawn in amps
E. Compressor :
i) Make and Modelii) Drive make and modeliii) Performanceiv) Current Drawn in amps
11. Power Supply (Customer’s scope) :
i) Supply Voltageii) Fluctuation, if any
12. Control Room :
i) Air Conditionedii) Pressurisediii) Dusty / Clean
Page 2of 3
Format: T-EPD-SR-F-025 Rev.: 1
::
:
::
:::
:
::
:::
:
:
::
:
::
:::
:::
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Installation & Commissioning ManualELECTROSTATIC PRECIPITATOR
13. Thermal Insulation:
14. Purging System :
i) Blower make and modelii) Heater make and modeliii) Motor make and modeliv) Performancev) Current Drawn in amps
15. Insulator Heater :
1) Performance2) Thermostat Setting3) Current Drawn in amps.
16. Hopper Heater & Level Controller :
Field No. HeaterPerformance
Heater CurrentDrawn in amps.
ThermostatSetting in °C
Level ControllerPerformance
Field 1
Field 2
Field 3
17. Name of the person & signature :carrying out Commissioning trials.
18. Name of the person & signature :witnessing Commissioning trials.
19. Name of the person & signature :handing over unit
20. Name of the person & signature :taking over unit.
Enclosure(s) :
Page 3of 3
Format: T-EPD-SR-F-025 Rev.: 1
:
:
:
:
:
:
:
:
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Installation & Commissioning Manual ELECTROSTATIC PRECIPITATOR
THERMAX LTDENVIRO DIVISIONPMT Complex, Behind PCMC BuildingMumbai-Pune Road, PimpriPUNE 411 003
Page 1 of 2
ACCEPTANCE REPORT
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
(B) Acceptance is granted (X -- cross the applicable box )
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 beencarried out.
(D) The supply, erection & commissioning completed as per the milestones listed below :-
(E)
Participant Name Company Date Signature1.
2.
3.
Completion Date
Delivery of equipment is completed
Erection & pre–commissioning tests completed
Commissioning
Trial run completed
Temporary taking over
Warrantee starts
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Installation & Commissioning ManualELECTROSTATIC PRECIPITATOR
(F) Corrective Work:
Sl.No. Nature of Work Responsibility
of CompletionScheduled Date
Participant Name Company Date Signature1.
2.
3.
THERMAX LTDENVIRO DIVISIONPMT Complex, Behind PCMC BuildingMumbai-Pune Road, PimpriPUNE 411 003
Page 2 of 2
ACCEPTANCE REPORT
Chapter 14
Precautions
ELE
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Following are the safety precautions to be taken for smooth functioning of ESP.
For Bio Mass Fired Boiler ESP
1. Introduction:
As agro waste fuels are much economical compared to fossil fuels there is a shift towards Agro waste fired
boilers in the recent times. The flue gases of Agro waste fired boilers contain very high-unburned carbon as
high as 20 to 60%.
The un-burnt carbon percentage goes up when the boiler is not operated within correct practices. The dust
with high-un-burnt carbon tends to be sticky. It may result in hopper choking. This also leads to collection of
dust in the hopper. This leads to smoldering and ignition due to internal friction leading to fire hazard. In order
to ensure that the minimum ash is present in the hopper and fire hazard is minimized, additional safety
interlocks / controls mentioned in ̀ B' are to be provided on all ESP's on Agro waste fired boilers.
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.
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Installation & Commissioning Manual ELECTROSTATIC PRECIPITATOR
c. Hopper Level Switches:
The RF capacitance type level switches will be provided in each hopper to sense the high dust level in the
hopper. The high level alarm will be wired to trip the respective TR set. Also potential free contact of High level
relay will be provided in the Aux. control panel, for fault annunciation & further tripping / stopping after a time
delay of 1 hour. Customer to wire the same for Boiler tripping /stopping. The necessary controls for tripping
the boiler will be in customers control panel. Probe tips of Level switches to be covered with sheet metal cover
from top to avoid dust settling from top leading to false alarm.
Smoldering of dust in the hopper: If the dust with high carbon content gets accumulated in the hopper
then it may catch fire & smoldering may start in the hopper. In order to detect the smoldering in the hopper,
RTDs will be provided in the hopper. The RTDs will be mounted very near to hopper bottom flange. The RTDs
will be connected to temperature controller in the ACP. Potential free contact of Temp. Controller will be wired
for tripping TR sets immediately. Potential free contact of hopper temperature high relay will be provided in the
Aux. control panel for necessary alarm & indication. Customer to wire the same for boiler tripping / stopping
without any time delay. The necessary controls for tripping the boiler will be in customer's control panel.
Thermostat can be used in place of RTD with prior concurrence from Engineering / Customer. Also the RTDs
should be supplied with SS thermowells.
The smoldering is mainly observed during the boiler start up / un-stabilised condition. Continuous dust
evacuation from all hoppers must be ensured to prevent the bridging & further smoldering in the dust. The
dust evacuation must be ensured irrespective of boiler start up or stabilised condition. To prevent the dust
bridging in the hoppers the hopper access doors must be flush to hopper wall from inside. Also the hopper
inside surface should be smooth without any projections to prevent the dust settlement & further bridging. All
temporary erection materials welded to hopper inside walls should be removed & ground smooth. Also
corner flats are to be provided at the joint of two panels.
d. Hopper vibrators:
Two numbers pneumatic vibrators should be provided for all the hoppers of ESPs for biomass fired boiler
applications. The vibrators will be mounted in bottom 1/3rd of the hopper on opposite sides. The type of
vibrator will be decided on case to case basis considering the compressed air availability / customer
preference. Fluidizing pads are not recommended.
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.
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Installation & Commissioning ManualELECTROSTATIC 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.
Summary of Points to be taken care for Biomass fied boiler E.S.P.
Sl. No. Item description
Two No. Of pneumatic vibrators should be provided for each hopper from outside. The vibrators
should be mounted in bottom 1/3rd of the hopper on opposite sides.
RAV of size 400 should be provided.
RAV speed should be 10 to 15 RPM to increase the dust discharge efficiency.
RTD sensor & transmitter 1 for each hopper to be provided
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 fortrough hoppers.
Hoppers shall have large poking holes of minimum 100 NB size to avoid dust bridging
1.
2.
3.
4.
5.
6.
7.
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Installation & Commissioning Manual ELECTROSTATIC PRECIPITATOR
Following interlocks are incorporated in the design, and to be ensured at site.
Sr. No.Equipment / Instrument Parameter
Signal Action
Rotary Air Lock valves provided
below I&II Field HoppersTrip
Alarm & Indication in ACP.
Trip signal is taken from zero
speed switch(This zero speed
switch is fixed near Rotary Air Lock
Valve Driven end )
Trip respective TR SET.
Signal to DCS
Rotary Air Lock valves - Over load
relay Trip.
Alarm & Indication in ACP. Trip respective TR SET.
Signal to DCS
If RAV faults persist for 2 hrs. Potential free contacts of Trip relay
will be provided in
ACP for alarm & indication + tripp
signal to Boiler.
Trip Boiler.
Signal to DCS
Dust conveying system shall be
ON all the time. If dust conveying
system trip/stopped.
Potential free contact for tripping
the all TR SET, all RAV.
All TR SETS, all RAV
shall trip.
Hopper Heater (provided to keep
the ash hoppers hot to increase
the flowability of ash- Normally,
used to be started before 4 hrs of
Boiler start up) Temperature High.
Alarm &Indication in ACP. Trip Hopper heater.
Signal to DCS
RTD to be mounted in each
Hopper, with TIC in ACP. Hopper
Temperature Very High
Alarm & indication in ACP,
Potential free contact for tripping
the Boiler.
Trip respective TR SET.
Signal to DCS.
Trip Boiler.
Transformer Sets (T.R.SET) Trip. Alarm &Indication in TRCC.
Potential free contact to DCS.
Signal to DCS
Hopper Level High.(Level probe
provided at about 60%of total
hopper height distance below the
collecting plates )
Alarm &Indication in ACP.
Immediately Trip the
corresponding Transformer sets.
Potential free contact in ACP for
DCS signal.
Trip respective TR SET.
Signal to DCS
Hopper Level High alarm persists
for 1 hr
Potential free contacts in ACP to
wire the same for Boi ler
Tripping/Stopping.
Trip Boiler.
Signal to DCS
In case Inlet temp. Sensed by TE
increases above set point.
TE to be mounted in the inlet duct
of ESP.
Alarm & Indication in ACP,
potential free contact for DCS
signal
Trip respective TR
Sets. Signal to DCS
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
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Installation & Commissioning ManualELECTROSTATIC PRECIPITATOR
I D FAN interlock.
If RAV or Screw conveyor stopped
/ tripped.
Potential free contacts in ACP,
Alarm & Indication in ACP
&potential free contact to trip the
ID FAN.
Trip I D FAN.
Signal to DCS.
Rapping system shall be ON all
the when ID FAN is running
irrespective of ESP is charged or
not.
ID Fan ON potential free contact
to MTP.
Purge Air System Interlock If Purge air system is not working
then trip the T/R sets.
Audio Visual Alarm
11.
12.
13.
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.
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Installation & Commissioning Manual ELECTROSTATIC PRECIPITATOR
Chapter 15
Safety Risk Assemblyfor ESP Activities
ELE
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The safety risk assessment for ESP erection and commissioning is attached with this.
All the needed precautions, given in the risk assessment should be adhered while doing erection and
commissioning of ESP.
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Installation & Commissioning Manual ELECTROSTATIC PRECIPITATOR
Safety Risk Assembly for ESP Activities
180
Installation & Commissioning ManualELECTROSTATIC PRECIPITATORRIS
K A
SSESSM
EN
T F
OR E
SP (
ELE
CTRO
STA
TIC
PREC
IPIT
ATO
R)
INSTA
LLA
TIO
N
Unlo
adin
g o
fm
ate
rials
1
a)
Fall
/ sl
ip o
f obje
cts
due
to inadeq
uate
handlin
g faci
litie
s
a)
Use
of PP
Es
like
safe
ty s
hoes
, H
and g
love
s, S
afe
ty h
elm
et
b)
Use
of ca
tagorise
d s
kille
d p
erso
nal
c) S
afe
ty introduct
ion to a
ll w
ork
men
& s
uper
viso
rs.
The
emer
gen
cy c
onta
ct
nos.
,lik
e Fi
re /
Am
bula
nce
/ N
eare
st H
osp
ital /
Secu
rity
are
to b
e m
ade
ava
ilable
at all
loca
tions
like
site
offic
e /
gro
und a
ssem
bly
are
a /
ere
ctio
n
are
a a
nd
als
o w
ith s
ite e
ngin
eers
/ c
ontract
or
super
viso
rs
b)
Dam
ages
to the
mate
rial due
to n
ot
follo
win
g the
safe
ty inst
ruct
ions
a)
Safe
ty inst
ruct
ions
are
to b
e fo
llow
ed d
uring u
nlo
adin
g o
f m
ate
rial. T
her
max
HO
to s
end the
safe
ty inst
ruct
ion /
ris
k ass
essm
ent to
site
s w
ell in
adva
nce
.
c) U
se o
f in
adeq
uate
/ w
rong /
under
size
m
ate
rial handlin
g tools
/ e
quip
men
t
b)
Spec
ial sa
fety
/ u
nlo
adin
g inst
ruct
ion for
colle
ctin
g p
late
s /
emitt
er e
lect
rodes
/ s
upport &
shaft insu
lato
r /
GD
scr
eens
are
to b
e ci
rcula
ted in a
dva
nce
.
c) U
nlo
adin
g inst
ruct
ions
to b
e se
nt to
site
alo
ngw
ith m
ate
rial.
a)
Use
of co
rrec
t si
ze tools
/ c
orr
ect ca
paci
ty e
quip
men
t fo
r unlo
adin
g the
mate
rial; b
)
Stora
ge
/ st
ack
ing
of m
ate
rials
2
a)
Caught in
bet
wee
n fin
ger
/ foot in
juries
a)
Use
of PP
Es;
b)F
ollo
w s
afe
mate
rial handlin
g p
roce
dure
; c)
Use
of pro
per
mate
rial handlin
g tools
& tack
les.
/ U
se o
f ca
togarise
d s
kille
d m
anpow
er /
U
se o
f co
rrec
t to
ols
/ tack
les
/ eq
uip
men
t fo
r st
ack
ing the
mate
rial
b)
Fall
of ESP
mate
rial due
to im
pro
per
st
ack
ing,
resu
lting in to a
ccid
ents
and
dam
age
to m
ate
rial
Use
of su
itable
wooden
sle
eper
s, s
upports
to a
void
fall
of st
ack
ed m
ate
rial. /
Provi
de
suffic
ient co
ver
like
tem
pora
ry s
hed
/ tarp
aulin
to a
void
the
dam
ages
to
the
mate
rial due
to d
ust
/ r
ain
.
c) G
as
Stora
ge
faci
lity
LPG
/ A
cety
lene
gas
stora
ge
faci
lity
Act
iviti
esSl
.N
o.
Haza
rds
Safe
ty P
reca
utio
n
Shift
ing o
f m
ate
rials
to s
ite (M
anual &
mec
hanic
al m
ate
rial
handlin
g e
quip
men
t)
3
a)
Bre
aka
ge
of ch
ain
slin
g /
wire
rope
& m
anila
rope
c) B
reaka
ge
of ch
ain
slin
g /
wire
rope
& m
anila
rope
b)
Ove
rloadin
g o
f eq
uip
men
t during
liftin
g
All
liftin
g m
ate
rial to
be
test
ed for
thei
r ca
paci
ty b
efore
taki
ng them
in to u
se.
Test
cer
tific
ate
to b
e obta
ined
fro
m c
om
pet
ent per
son.
This
is
required
as
per
fact
ories
act
19
48
.
All
liftin
g m
ate
rial /
tools
/ tack
les
shall
be
chec
ked p
erio
dic
ally
, fo
r any
def
ects
those
arise
s during its
use
and s
top its
usi
ng if any
def
ects
found
i) V
erifi
catio
n o
f lo
adin
g p
oin
t of hyd
ra /
chain
pulle
y blo
ck /
tes
t ce
rtifi
cate
s of w
ire
ropes
ii)
Iden
tific
atio
n /
mark
ing o
f w
eight on the
job b
eing lift
ed
Safe
ty R
isk
Ass
essm
ent D
ocu
men
t (E
SP) N
o.:
TL/
EN
V/E
SP/S
afe
ty/0
01
Rev
0
Contract
or
& C
ust
om
er
Contract
or
& C
ust
om
er
Ther
max
Engg.
Ther
max
HO
Ther
max
HO
Ther
max
HO
Contract
or
& C
ust
om
er
Contract
or
& C
ust
om
er
Res
ponsi
bili
ty
Contract
or
& C
ust
om
er
Contract
or
& C
ust
om
er
Contract
or
& C
ust
om
er
Contract
or
& C
ust
om
er
Contract
or
& C
ust
om
er
Contract
or
& C
ust
om
er
181
Installation & Commissioning Manual ELECTROSTATIC PRECIPITATOR
c) Inadeq
uate
lift
hook
posi
tion ( V
ertic
al
& h
orizo
nta
l lif
ting)
f) A
ccid
ent or
Dam
ages
to the
mate
rial
while
liftin
g d
ue
to lack
of fo
cus
on the
job (e.
g.
talk
ingove
r m
obile
while
oper
atin
g c
rane
/ hyd
ra /
fork
lift/
win
ch e
tc.) /
or
not usi
ng o
f ca
tegorize
d s
kille
dm
anpow
er
Ele
ctrica
l co
nnec
tion
for
erec
tion /
gro
und
ass
embly
work
a)
Unsa
fe p
ract
ice
of ca
ble
layi
ng fro
m
elec
tric
al panel
to s
ite d
istrib
utio
n b
oard
.
a) A
ll el
ectric
al ca
ble
s are
to b
e la
id d
ow
n s
afe
ly e
ither
under
gro
und o
r ove
rhea
d a
nd thro
ugh p
ipe
conduit.
b)
Unsa
fe p
ract
ices
of ca
ble
connec
tions
/ jo
ints
(hand lam
ps
/ to
ols
/ e
arthin
g)
a) M
ain
dis
trib
utio
n b
oard
ELC
B,
of su
ffic
ient ca
paci
ty /
ratin
g,
should
be
pro
vided
with
TPN
faci
lity,
nea
r ESP
ere
ctio
n s
ite.
c) P
roper
earthin
g s
hould
be
pro
vided
for
all
elec
tric
al applia
nce
s bei
ng u
sed
at si
te.
Earthin
g p
oin
ts to b
e ch
ecke
d a
nd e
nsu
red.
Act
iviti
esH
aza
rds
Safe
ty P
reca
utio
n
Gro
und a
ssem
bly
work
a)
Unev
en g
round flo
or
resu
lting s
lippin
g
of m
ate
rial during a
ssem
bly
b)
Wel
din
g s
park
s /
fire
/ele
ctrica
l sh
ock
ca
usi
ng fire
haza
rds
and d
am
ages
to
mate
rial &
lea
din
g to a
ccid
ents
e) P
roper
safe
cove
r to
be
pro
vided
to a
ll el
ectric
al applia
nce
s /
board
s sp
ecia
lly in r
ain
y se
aso
n
Leve
l th
e gro
und b
y back
fill
ing the
soil
at le
ast
8-1
0 d
ays
prior
to g
round
ass
embly
work
, to
avo
id d
elay
in a
ctiv
ity.
a) D
o n
ot ke
ep the
flam
mable
ite
ms
(e.g
. ace
tyle
ne
or
LPG
cyl
inder
s) n
ear
wel
din
g /
cutti
ng a
rea.
b) Ensu
re the
ava
ilabili
ty o
f fir
e ex
tinguis
her
(C
O2
or
wate
r /
sand) or
suffic
ient
wate
r w
hile
doin
g the
hot w
ork
nea
rby
flam
mable
mate
rial.
Contract
or
& C
ust
om
er(C
hec
k th
e m
ark
ing o
n
the
com
ponen
t in
pla
ce
of lu
gs.
)
Contract
or
& C
ust
om
er
Contract
or
& C
ust
om
er
Res
ponsi
bili
ty
Contract
or
& C
ust
om
er
Contract
or
& C
ust
om
er
Contract
or
& C
ust
om
er
Contract
or
& C
ust
om
er
Contract
or
& C
ust
om
er
Contract
or
& C
ust
om
er
Shift
ing o
f m
ate
rials
to s
ite (M
anual &
mec
hanic
al m
ate
rial
handlin
g e
quip
men
t)
Pro
per
lift
ing h
ooks
are
to b
e c
onsi
dere
d d
uri
ng d
esi
gn s
tage a
nd
sam
e t
o b
e p
rovi
ded d
uri
ng f
abri
cation s
tage.
i) T
o a
void
such
typ
e of danger
ous
unsa
fe a
cts,
use
of m
obile
phones
should
be
avo
ided
stric
tly.
Als
o u
n-n
eces
sary
com
munic
atio
n w
ith o
per
ato
rs m
ust
be
avo
ided
.
ii) T
he
mate
rial handlin
g e
quip
men
t's lik
e cr
ane,
hyd
ra,
fork
lift m
ust
be
oper
ate
d b
y A
UTH
ORIZ
ED
LIC
EN
SE H
OLD
ER D
RIV
ERS
ON
LY.
iii) A
lcoholic
consu
mptio
n s
tric
tly p
rohib
ited d
uring w
ork
ing h
ours
. at si
te
oper
atin
g c
rane
and o
ther
mate
rial handlin
g e
quip
men
t /
vehic
les.
Contract
or
& C
ust
om
er
Contract
or
& C
ust
om
er
b) Sa
fety
sig
n to b
e dis
pla
yed for
cautio
n,
at all
such
loca
tion.
b) C
able
ext
ensi
on b
oard
s sh
ould
be
use
d.
d) A
ll w
eldin
g m
ach
ines
/ o
ther
ele
ctrica
l to
ols
are
to b
e te
sted
at si
te (fo
r m
egger
& c
urr
ent) for
corr
ect cu
rren
t ra
ting.
Contract
or
& C
ust
om
er
Contract
or
& C
ust
om
er /
Ther
max
f) p
rovi
de
suffic
ient fir
e ex
tinguis
her
/ s
and b
uck
ets
nea
r m
ain
DB &
wel
din
gm
ach
ines
.
c) E
nsu
re that th
e su
rface
s bei
ng w
elded
are
in d
ry c
onditi
on.
Als
o e
nsu
re that
the
wel
der
is
not ove
r sw
eate
d w
hic
h c
an c
ause
acc
iden
t due
to e
lect
rica
l sh
ock
Contract
or
& C
ust
om
er
3 4
Sl.
No.
5
182
Installation & Commissioning ManualELECTROSTATIC PRECIPITATOR
c) A
ccid
ents
due
to g
as
cutti
ng /
back
fir
e /
leaka
ge
of gas
d) A
ccid
ents
due
to g
rindin
g s
park
s /
eye
inju
ries
/ fire
/ el
ectric
al sh
ock
a) Fa
ll of der
rick
/ fall
of lif
ting
arr
angem
ent &
liftin
g s
upport
arr
angem
ent
Adeq
uate
safe
ty p
reca
utio
ns
like
are
to b
e ta
ken -
i) G
uy
ropes
, ii)
Ver
ticalit
y of
der
rick
after
loadin
g,
iii) Barr
icade
the
are
a w
hile
ere
ctin
g d
errick
, iv
) Exp
erie
nce
d&
ski
lled r
igger
s nee
d to b
e en
gaged
for
der
rick
ere
ctio
n
b) Fo
llow
safe
mate
rial handlin
g p
roce
dure
Act
iviti
esH
aza
rds
Safe
ty P
reca
utio
n
Gro
und a
ssem
bly
work
d) Fa
tal acc
iden
t due
to n
ot usi
ng p
roper
lif
ting fra
me
/ to
ols
/ lock
ing a
rrangem
ents
fo
r m
ate
rial bei
ng lift
ed.
c) U
se o
f pro
per
lift
ing tools
/ tack
les
(with
tes
t ce
rtifi
cate
s)
Contract
or
& C
ust
om
er
Contract
or, C
ust
om
er,
Ther
max
Engin
eer
Contract
or
& C
ust
om
er
Contract
or
& C
ust
om
er
Contract
or
& C
ust
om
er
Contract
or
& C
ust
om
er
a) U
se o
f PP
Es
a) Pr
ovi
de
adeq
uate
space
for
gro
und a
ssem
bly
of co
mponen
ts.
Contract
or
& C
ust
om
er
e) E
nsu
ring s
uffic
ient lif
ting lugs
for
mate
rial bei
ng lift
ed
a) U
nder
any
circ
um
stance
s, u
se o
f lif
ting fra
me
& a
ssem
bly
jig
must
be
ensu
red,
as
per
Ther
max
dra
win
g.
Contract
or, C
ust
om
er,
Ther
max
Engin
eer
(Not
follo
win
g the
safe
typre
cautio
n,
will
affec
t th
eESP
com
ple
tion s
ched
ule
and p
erfo
rmance
of ESP
.)
Sl.
No.
5
a) U
se o
f co
rrec
t si
ze c
utti
ng s
ets
/ cu
tting n
ozz
les
/ back
fire
arr
esto
r to
be
done.
The
gas
cylin
der
s are
to b
e ke
pt in
ver
tical posi
tion,
pre
fera
bly
in c
ylin
der
tro
lley.
Use
of te
sted
gas
regula
tors
with
pre
ssure
gauges
. U
se the
cylin
der
s w
ith g
uard
.U
se p
roper
hose
pip
e w
ith s
tandard
colo
ur
codin
g a
nd p
roper
hose
cla
mps
to b
euse
d to c
onnec
t th
e hose
s.
b) Ensu
re the
ava
ilabili
ty o
f fir
e ex
tinguis
her
or
suffic
ient w
ate
r w
hile
doin
g the
hot w
ork
.
e) A
ccid
ents
causi
ng to h
and /
fin
ger
in
juries
during h
am
mer
ing /
fitt
ing
f) A
ccid
ents
due
to in-s
uffic
ient te
mpora
rysu
pports
to c
om
ponen
t ca
usi
ng fata
l acc
iden
t /
dam
ages
to m
ate
rial
Use
of PP
Es
like
hand g
love
s, s
afe
ty g
oggle
s, e
lect
rica
l applia
nce
s w
ith p
roper
earthin
g s
hould
be
use
d.
Use
of PP
Es
like
hand g
love
s, s
afe
ty g
oggle
s, p
roper
tools
lik
e w
ooden
sl
eeper
s, p
ack
ings
while
doin
g the
work
.
Use
of su
ffic
ient su
pport to a
void
falli
ng o
f co
mponen
t bei
ng a
ssem
ble
d.
Contract
or
& C
ust
om
er
6G
round a
ssem
bly
work
c) U
se o
f pro
per
mate
rial handlin
g tools
& c
) ta
ckle
sd) Pe
riodic
safe
ty tra
inin
g
b) H
and a
nd foot in
juries
c) A
ccid
ents
res
ulti
ng in loss
of m
an-d
ays
and a
ffec
ting e
quip
men
t per
form
ance
d
ue
toin
adeq
uate
faci
lity
/ arr
angem
ent
for
mate
rial bei
ng lift
ed
b) A
ll gro
und a
ssem
blie
s to
be
done
on p
roper
lev
eled
pla
tform
d) A
dher
ence
to the
sequen
ce o
f er
ectio
n,
alig
nm
ent &
wel
din
g
f) E
nsu
re the
dry
run o
f th
e m
ate
rial handlin
g e
quip
men
t, b
efore
lift
ing the
mate
rial.
Contract
or
& C
ust
om
er
Contract
or, C
ust
om
er,
Ther
max
Engin
eer
Contract
or
& C
ust
om
er
Contract
or
& C
ust
om
er
Contract
or, C
ust
om
er,
Ther
max
Engin
eer
Contract
or
& C
ust
om
er
Res
ponsi
bili
ty
183
Installation & Commissioning Manual ELECTROSTATIC PRECIPITATOR
e) A
ccid
ents
due
to lack
of
know
ledge
of
equip
men
t &
poor
com
munic
atio
n
/
inadeq
uate
w
ork
pro
cedure
&
w
rong
erec
tion seq
uen
ce
a) Fa
tal acc
iden
t /
per
manen
t dis
abili
tya) U
se o
f PP
Es
i.e.
safe
ty b
elt, h
elm
et,
safe
ty s
hoes
, hand g
love
s, s
afe
ty g
oggle
set
c.
Act
iviti
esH
aza
rds
Safe
ty P
reca
utio
n
Gro
und a
ssem
bly
work
b) A
ll to
ols
, bei
ng u
sed a
t hig
h e
leva
tion s
hould
be
tied to job,
with
pro
per
ch
ain
, to
not to
allo
w to fall.
Contract
or
& C
ust
om
er
Contract
or
& C
ust
om
er
Contract
or
& C
ust
om
er
c) P
rovi
de
the
safe
ty b
arr
icade
tapes
bel
ow
work
ing a
rea to a
void
the
entry
of
per
sonal.
b) Fo
r ef
fect
ive
com
munic
atio
n,
arr
ange
mee
ting for
allo
catin
g r
esponsi
bili
ties,
bef
ore
com
men
cing the
work
.
Contract
or, C
ust
om
er,
Ther
max
Engin
eer
Work
ing a
t hei
ght
b) In
adeq
uate
faci
lity
to r
each
at hig
h
elev
atio
n,
resu
lting into
fata
l acc
iden
t
c) F
alli
ng o
f to
ols
/ s
crap -
deb
ris
/ er
ectio
n m
ate
rial
a) N
o m
an m
ove
men
ts,
on g
round /
low
er e
leva
tion,
is a
llow
ed w
hile
any
work
(cutti
ng /
ere
ctio
n /
mate
rial lif
ting /
fitt
ing) is
goin
g o
n a
t hig
her
ele
vatio
n.
Contract
or
& C
ust
om
er
Contract
or
& C
ust
om
er
Res
ponsi
bili
ty
a) Th
e w
ork
gro
up /
super
viso
r sh
ould
be
brief
ed o
n the
equip
men
t kn
ow
ledge
/ a
ctiv
ity k
now
ledge.
c) F
ollo
w the
sequen
ce o
f m
echanic
al in
stalla
tion.
d) A
lways
res
ponsi
ble
, auth
orise
d p
erso
n m
ust
be
ava
ilable
outs
ide
ESP
, w
hile
work
men
are
work
ing insi
de
ESP
.
Contract
or, C
ust
om
er,
Ther
max
Engin
eer
Contract
or, C
ust
om
er,
Ther
max
Engin
eer
d) Ph
ysic
al fit
nes
s /
Poor
visi
on w
ork
men
w
hile
work
ing a
t hei
ght
e) H
igh w
ind flo
w c
ausi
ng d
istu
rbance
in
work
act
ivity
whic
h r
esults
in a
ccid
ent
b) Pr
ovi
sion o
f pro
per
sca
ffold
ing a
nd ladder
arr
angem
ent fo
r w
ork
ing p
eople
at hig
her
ele
vatio
n.
a) Pr
ovi
de
pro
per
ladder
s to
have
appro
ach
to E
SP c
olu
mns
/ girder
s after
erec
tion.
Use
of fa
ll arr
esto
r fo
r th
e w
ork
ing m
en a
t hei
ght.
b) Pr
ovi
de
the
lugs
/ su
pports
on u
pper
end o
f m
ate
rial bei
ng e
rect
ed,
so that
work
men
can h
ook
the
safe
ty h
arn
ess
while
doin
g the
work
at hig
h e
leva
tion.
a) Ph
ysic
al fit
nes
s ce
rtifi
cate
to b
e obta
ined
by
auth
orise
d p
hys
icia
nb) C
ontin
uous
rest
less
work
, w
hic
h c
an a
ffec
t w
ork
men
fitn
ess,
should
not be
allo
wed
.
a) N
o w
ork
should
com
men
ce,
if hea
vy w
indflo
w a
ffec
ts in s
afe
work
conditi
ons
Contract
or
& C
ust
om
er
Contract
or
& C
ust
om
er
Contract
or
& C
ust
om
er
Contract
or
& C
ust
om
er
Ele
ctrica
l In
stalla
tion
a) Im
pro
per
lock
out w
hile
work
ing w
ith
elec
tric
al liv
e pow
er s
upply
during
inst
alla
tion /
seq
uen
ce o
f ca
ble
ter
min
atio
n
b) Im
pro
per
way
of ca
ble
pulli
ng
c) U
nsa
fe p
ract
ices
of ca
ble
join
ts
(hand lam
ps
/ to
ols
/ e
arthin
g)
a) Ensu
re that th
e fu
ses
from
inco
mer
panel
s and p
ut th
e board
of 'M
EN
AT
WO
RK
. D
O N
OT
SWIT
CH
ON
'.b) Fo
r ca
ble
ter
min
atio
n,
the
sequen
ce s
hall
be
follo
wed
fro
m m
ain
equip
men
t to s
upply
poin
t e.
g.
MC
C /
AC
P to
TRC
C o
r TR
CC
to T
R s
et.
Firs
t TR
set
cable
term
inatio
n to b
e done
follo
wed
by
term
inatio
n a
t TR
CC
and then
at M
CC
/ A
CP.
a) W
hile
pulli
ng the
cable
s ve
rtic
ally
upw
ard
s, s
uffic
ient w
ork
men
to b
e dep
loye
d a
t va
rious
elev
atio
n w
ith u
se o
f PP
Es.
b) Pr
oper
/su
itable
arr
angem
ent to
be
ensu
red for
pulli
ng /
dro
ppin
g the
cable
.
a) C
able
ext
ensi
on b
oard
s sh
ould
be
use
d.
b) Pr
oper
earthin
g s
hould
be
pro
vided
for
all
elec
tric
al applia
nce
s bei
ng u
sed
at si
te.
Contract
or
& C
ust
om
er
Contract
or
& C
ust
om
er
Contract
or
& C
ust
om
er
Contract
or
& C
ust
om
er
Contract
or
& C
ust
om
er
Contract
or
& C
ust
om
er
Sl.
No.
6 7 8
184
Installation & Commissioning ManualELECTROSTATIC PRECIPITATOR
Act
ivitie
sH
aza
rds
Safe
ty P
reca
ution
d) Pr
oper
com
mun
icatio
n to
ols
mus
t be
used
whi
le c
ond
uctin
g G
D tes
t.
e) A
lways
res
pons
ible
, aut
horise
d p
erso
n m
ust be
ava
ilable
nea
r, out
side
ESP,
whi
le c
ond
uctin
g the
GD
tes
t.
b) Fo
llow
the
inst
alla
tion
seque
nces
Pre-
Com
mis
sioni
ng /
Com
mis
sioni
ngA
ctiv
ities
a) Se
rious
acc
iden
t due
to in
hala
tion
of dus
tin
side
ESP
(Conf
ined
Space
) dur
ing E
SP G
D tes
t
a) N
o h
ot w
ork
to b
e done
nea
r el
ectric
al /
inst
rum
ent ite
ms,
with
out
put
ting
pro
per
cove
r on
the
item
s.
c) E
qui
pm
ent aw
are
ness
to b
e giv
en to the
work
men
Cont
ract
or,
Cus
tom
er,
Ther
max
Engin
eer
Cont
ract
or,
Cus
tom
er,
Ther
max
Engin
eer
b) H
aza
rds
ass
oci
ate
d w
ith e
lect
rica
l,in
stru
men
tatio
n, m
echa
nica
l work
s i.e
. en
try
inco
nfin
ed s
pace
(na
rrow
are
a in
side
ESP)
, no
n ava
ilabili
ty o
f in
terlock
ing s
yste
m &
impro
per
com
mun
icatio
n fo
r th
e w
ork
act
ivity
c) S
erio
us a
ccid
ent due
to p
oor
illum
inatio
nin
side
ESP
(conf
ined
space
)
a) Pr
oper
work
per
mit
mus
t be
obta
ined
ens
urin
g p
ow
er lo
ck o
ut /
men
on
work
at pane
ls,
bef
ore
ent
erin
g E
SP in
side.
Proper
work
per
mit
mus
t be
obta
ined
ens
urin
g p
ow
er lo
ck o
ut /
men
on
work
at pane
ls,
bef
ore
ent
erin
g E
SP in
side.
Cont
ract
or,
Cus
tom
er,
Ther
max
Engin
eer
Elec
tric
al I
nsta
llatio
nd) H
ot w
ork
(gas
cutti
ng /
wel
din
g /
hea
ting e
tc.)
near
elec
tric
al /
inst
rum
enta
tion
item
s lik
e ca
ble
s,TR
set
s, H
eate
rs,
Leve
l sen
sors
etc
.
Cont
ract
or
& C
usto
mer
Acc
iden
ts d
ue to im
pro
per
crim
pin
g /
work
man
ship
/ in
adeq
uate
mea
suring
inst
rum
ents
Use
of pro
per
tools
/ tack
les
for
cable
term
ination /
crim
pin
g.
All
cable
are
to
be term
inate
d w
ith u
se o
f lu
gs.
All
act
ivitie
s are
to b
e d
one b
y ca
tegorize
d
skill
ed p
ers
onal. P
roper
and c
alib
rate
d m
easu
ring inst
rum
ents
are
to b
e
pro
vided w
hile
doin
g the w
ork
.
e) Inj
ury
to fin
ger
s /
hand
s w
hile
rem
ovi
ng c
able
insu
latio
n /
arm
our
with
kni
fe
f) O
per
atio
n of pane
l sw
itch
with
nake
d h
and
s i.e
.sw
itchi
ng O
N p
ane
ls w
ithout
usi
ng p
ane
l hand
les
a) U
se o
f PP
E m
ust be
ensu
red
b) U
se o
f no
n-st
and
ard
tools
like
kni
fe /
cut
ter
mus
t be
stopped
.
a) Re
pla
ce the
dam
aged
pane
l hand
les
b) U
se the
sui
table
insu
late
d tools
like
, if
requi
red in
urg
ency
Cont
ract
or
& C
usto
mer
Cont
ract
or
& C
usto
mer
Cont
ract
or
& C
usto
mer
Cont
ract
or
& C
usto
mer
Cont
ract
or,
Cus
tom
er,
Ther
max
Engin
eer
b) U
se o
f PP
Es m
ust be
ensu
red b
efore
ent
erin
g in
side
ESP
for
GD
tes
t.
c) B
efore
ent
erin
g in
side
ESP, e
nsur
e th
at th
ere
is n
o d
ust pass
ing thr
oug
h ES
P.Th
is c
an
be
done
by
runn
ing the
ID
fan
till s
tack
is c
lean
visu
ally
, bef
ore
en
tering
insi
de
ESP.
Cont
ract
or,
Cus
tom
er,
Ther
max
Engin
eer
Cont
ract
or,
Cus
tom
er,
Ther
max
Engin
eer
Cont
ract
or,
Cus
tom
er,
Ther
max
Engin
eer
Cont
ract
or,
Cus
tom
er,
Ther
max
Engin
eer
Suffi
cien
t illu
min
atio
n of 2
4V /
10
0W
lam
ps
are
to b
e pro
vided
. M
inim
um tw
ola
mps
mus
t be
pro
vided
per
gro
up,
out
of th
is 1
mus
t be
used
as
stand
by
Cont
ract
or
& C
usto
mer
Sl.
No.
98
Resp
onsi
bili
ty
185
Installation & Commissioning Manual ELECTROSTATIC PRECIPITATOR
Act
ivitie
sH
aza
rds
Safe
ty P
reca
ution
Use
of ea
r m
uff /
ear
plu
gs
Pre-
Com
mis
sioni
ng /
Com
mis
sioni
ngA
ctiv
ities
Cont
ract
or
& C
usto
mer
a) W
ear
suita
ble
PPE
s
b) Bef
ore
ent
erin
g a
roun
d /
insi
de
equi
pm
ent, m
easu
re h
aza
rdous
gase
s (C
O)
leve
l and
carr
y th
e in
stru
men
t til
l per
son
com
es o
ut o
f ha
zard
ous
zone
.
Resp
onsi
bili
ty
d)
Chance
s of
explo
sions
insi
de
ESP
i.e
. due
to
CO
acc
um
ula
tion in
side
ESP
/
carr
y ove
r of
unco
ntrolle
d,
unburn
ed i
nsi
de
ESP
/ i
mpro
per
sequen
ce o
f pla
nt
start u
p o
r sh
ut
dow
n -
All
resu
lting
into
ESP
in
tern
al
dam
ages
/
ESP
dam
age
/ Fa
tal
Acc
iden
t /
Hea
vy
loss
es
to
pro
per
ty
a) In
stall
CO
ana
lyze
r. ES
P TR
set
s trip
pin
g in
terlock
ing to b
e in
corp
ora
ted if
C
O le
vel i
s m
ore
tha
n 2
%
b) In
case
if E
SP ID
fan
is tripped
for
any
rea
son,
ESP
pur
ge
air b
low
er s
houl
d
be
switc
hed O
FF im
med
iate
ly.
b) A
rres
t all
fals
e air lea
kages
insi
de
ESP
whic
h s
upply
oxy
gen
to the
fire.
The
sourc
es o
f fa
lse
air lea
kages
mig
ht be
from
Rota
ry A
irlo
ck V
alv
es,
Insp
ectio
nD
oors
, H
opper
By-
pass
chute
Cont
ract
or
& C
usto
mer
Cont
ract
or
& C
usto
mer
Work
ing in
haza
rdous
zone
Inhala
tion &
Exp
osu
re o
f dust
, m
ist, fum
es,
gase
ous
Hig
h n
ois
e le
vels
Exp
osu
re to h
igh tem
per
atu
reU
se the
sui
table
PPE
s.
Indiv
idua
l
Indiv
idua
l (C
usto
mer
to
giv
e C
O a
naly
zer)
Indiv
idua
l
Indiv
idua
l
Sl.
No.
9 10
Chapter 16
Stack SamplingProcedure
ELE
CTRO
STA
TIC
PREC
IPIT
ATO
R
Following are the guidelines for conducting the ESP performance testing.
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
Installation & Commissioning Manual ELECTROSTATIC PRECIPITATOR
Stack Sampling Procedure
At Outlet / Stack of ESP
a. Flue Gas Temperature (in C)
b. Flue Gas Velocity (in m/sec)
c. Flue Gas Volumetric Flow (Am3/sec)
d. Dust Emission (mg/Nm3)
e. Moisture content in flue gas (in % vol. / vol.)
4. The sampling shall be started after ensuring that the up-stream process is running at steady state condition on
designed load.
5. At inlet & outlet of ESP, each three samples shall be taken and average of these three samples shall be treated
as the result.
6. For rectangular / round duct / stack, the sampling ports shall be fixed using the guide lines mentioned in the
above referred standard, in order to take sampling based on equal area method.
7. To conduct the proximate and ultimate analysis of fuel, the fuel samples shall be collected for the fuel being
fired at the time of sampling.
8. To conduct chemical analysis of fly ash, dust samples from ESP hoppers discharge points shall be collected
during the testing.
9. The entire sampling need to be planned and witnessed by all concern, and the readings shall be jointly
recorded.
Sampling Test Calculations and Results
All the samples that are collected during testing should be sent to testing laboratory for further testing and analysis.
Then final results / analysis and calculations shall be submitted.
Following is the standard template, used to tabulate the ESP test data, actual Vs design. This is for reference only.
Sl. No
Temperature in ºC (At ESP inlet)
Gas Flow in AM³/hr
Inlet Dust Concentration
in gm/NM³
Outlet Emission in mg/NM³
Design Actual Design Design DesignActual Actual Actual
1.
2.
3.
Avg.
187
Installation & Commissioning ManualELECTROSTATIC PRECIPITATOR
188
Installation & Commissioning Manual ELECTROSTATIC PRECIPITATOR
Sampling Port Arrangement Sketch No. 107
189
Installation & Commissioning ManualELECTROSTATIC PRECIPITATOR
Sketch No. 108Sampling Port Arrangement
EN
VIR
O D
IVIS
ION
Chapter 17
List of Two YearsOperating Spares
190
Installation & Commissioning Manual ELECTROSTATIC PRECIPITATOR
List of Two Years Operating Spares
TWO YEARS OPERATING SPARES FOR ESP ( 90 / 120 KV Rating )
SR NO. DESCRIPTION QUANTITY
Support Insulator
Shaft Insulator
Support insulator heater
Rapper Coil with shield
Gasket for support insulators(1 set consists of 12 gaskets)
Hypalon Boot
Clamp for Hypalon Boot Big End
Clamp for Hypalon Boot Small End
PLC CARD for Micro Tapper Panel
HMI for Micro Tapper Panel
SMPS 2A for Micro Tapper Panel
Row Board for Micro Tapper Panel
Column Board for Micro Tapper Panel
DC Thyrister Unit for Micro Tapper Panel
Hopper level switch
Purge air filter
Diode for rapper
Firing Module for TR set control Panel
Controller for TR Set
Thermostat for hopper heater
2 Nos.
2 Nos.
2 Nos.
2 Nos.
2 Sets.
12 Nos.
12 Nos.
1 Nos.
1 Nos.
12 Nos.
1 Nos.
1 Nos.
1 Nos.
1 Nos.
1 Nos.
1 Nos.
12 Nos.
1 Nos.
1 Nos.
1 Nos.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
For quick response please mention our equipment OC No. in the purchase enquiry.
For example E 7404 or E - 7423
Whome to contact
In case of problemEN
VIR
O D
IVIS
ION
191
Installation & Commissioning Manual ELECTROSTATIC PRECIPITATOR
SERVICE MANAGERHEAD OFFICE
CORPORATE REGIONALMANAGER
SERVICE MANAGERREGIONAL OFFICE
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.
TEL:011-26145319 FAX:011-26145311
KOLKATA REGIONTHTHERMAX LIMITED, AZIMGANG HOUSE, 5 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
DIVISIONAL HEAD
THERMAX LIMITED, ENVIRO DIVISION, PMT COMPLEX, BEHIND PCMC BUILDING., MUMBAI-PUNE ROAD,
PUNE 411 018.
TEL:020-66122999 FAX:020-27426532 / 33
THERMAX LIMITED, GREEN HOUSE, 148, MUMBAI-PUNE ROAD, PIMPRI, PUNE - 411 018.
TEL:020-27426013
Email: [email protected], [email protected]
CHENNAI REGION
THERMAX LIMITED, 312, ANNA SALAI, TEYNAMPET, CHENNAI - 600018.
TEL:044-24353831(4LINES) FAX:044-24353841 Email:[email protected]
DELHI REGION
THERMAX LIMITED, 9, COMMUNITY CENTRE, BASANT LOK, NEAR PRIYA CINEMA, NEW DELHI 110057.
TEL:011-26145319 FAX:011-26145311 Email:[email protected]
KOLKATA REGIONTH
THERMAX LIMITED, AZIMGANG HOUSE, 5 FLOOR, 7, CAMAC STREET, KOLKATA.
TEL:033-22826711/12/13 FAX:033-22826796 Email:[email protected]
MUMBAI REGION
THERMAX LIMITED, DHANRAJ MAHAL, CHATRAPATI SHIVAJI MARG, COLABA, MUMBAI 400039.
TEL:022-22045391 FAX:022-22040859 Email:[email protected]
In case of problem, please contact :
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
ENVIRO DIVISION
THERMAX LIMITED
X