erection manual - tl design esp

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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

ii

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


Guidelines on Health & Safety Measures

Chapter 2

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Guidelines on Health & Safety Measures

2

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.


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.

3

ELECTROSTATIC PRECIPITATOR Installation & Commissioning Manual

4


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.


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.

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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.


10

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.


11

Sketch No. 001 - Handling Instructions


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.


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


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

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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

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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

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on

As

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g

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per

speci

ficatio

n

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col

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W W W W

P P P P P P P

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W W W W W W

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P P P P

W W W W

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14


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

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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

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on &

H

ealth

ines

sSt

raig

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ess

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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%

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per

Dra

win

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on

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on

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per

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s per

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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


16


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

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nG

ood C

onditio

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s per

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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


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


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


21


Sketch No. 002 Footing Center Line Marking

Sketch No. 003

22


Sketch No. 004 Footing Center Line Marking

23


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


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.

25


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.

26


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.

27


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.

28


29


Sketch No. 006 Nozzle Assy Panel Fit-Up

30


Sketch No. 007 Casing Column Assembly (With Side Panel)

9 10 11

12 13

Sketch No. 008 Casing And Hopper Fit-Up Details


31

15

1617

18 19



32


Sketch No. 21 Sketch No. 22

33


Sketch No. 23 Hopper Assembly Fit-Up


34


Hopper Assembly Fit-Up

Sketch No. 27

Sketch No. 29Sketch No. 28

Sketch No. 26

35


Top High Voltage Support Frame Welding Details

Sketch No. 30

36


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

37


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.

38


39


Support Structure Alignment

Sketch No. 31

40


Structure Column Erection

Sketch No. 32

41


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.


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

42


43


Expansion Bearing Assembly

Sketch No. 33

Sketch No. 34

44


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


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.

45


46


Casing Column Alignment

Sketch No. 36

47


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.

48


49


Staircase, Railing, Landing Fit-Up

Sketch No. 38

50


Staircase, Railing, Landing Fit-Up



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.

51


52


Floating Channel Alignment

Sketch No. 43

53


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.

54


55


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.

56


57


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.

58


59


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.

60


61


Erection Tools

Sketch No. 49

62


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.

63


64


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.

65


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.

66


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.

67


68


Collecting Plate Plumbness

Sketch No. 52

69


Collecting System Fit-Up Details

Sketch No. 53

Sketch No. 55

Sketch No. 56

Sketch No. 54

70





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.

71


72


*

*

H.V. Assembly Suspension

Sketch No.63

73


Penthouse Fit-Up Details

Sketch No. 64

74



Sketch No. 65

75



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.

76


77


Rigitrode System Fit-Up Details

Sketch No. 67

78


Sketch No. 68


Sketch No. 69



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.

79


80


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.

81


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.

82


83


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

84


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.

85


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.

86


87


Casing Baffle Arrangement

Sketch No. 76

88



Sketch No. 77

89



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.

90


91


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.

92


93



Sketch No. 80

94




95


Inlet & Outlet Nozzle Rapping Fit-Up

Sketch No. 83

96


Inlet & Outlet Nozzle Rapping Fit-Up

Sketch No. 84

97


G. D. Screen Assy. Fit-Up

Sketch No. 85

98


G. D. Screen Assy. Fit-Up


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).

99


100


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.

101


102


Hopper Baffle Arrangement

Sketch No. 92

103


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.

104


105


Monorail Structure Assembly

Sketch No. 94

106


Structure Site Welding

Sketch No. 111

TYPICAL SITE WELDING DETAILSFOR SUPPORT STRUCTURE / MONORAIL STRUCTURE

107


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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.

108


109


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.

110


111




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.

112


113



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.


+Center of rapper boot mounting in line with center of respective anvil beam and spirit level of anvil beam.


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.

114


115



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.


+Center of rapper boot mounting in line with the center of respective single end tapered coupling.


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.

116


117



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.

118


119


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.

120


+Operational Philosophy :For accessibility to ESP internals through access door, following sequence to be followed.

121


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

122


123


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

124


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


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.

126


127


D.U

.NO

.D

ES

CR

IPT

ION

Insulation Arrangement

Sketch No. 110-A

128



Sketch No. 110-B

129



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

138


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.

139


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.

140


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


142


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


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


145


Earthing Arrangement of Control Panel And TR Set For ESP

Sketch No. 113

146


Hook-Up For Insulator Heater

Sketch No. 114

147


Hook-Up For Level Switch

Sketch No. 115

148


Hook-Up For Temp. Element

Sketch No. 116

149


Sketch No. 117

Hook-Up For Temp. Element

150


Hook-Up For Thermostat

Sketch No. 118

151


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


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


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


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.

157


158


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


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.

160


161


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



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.



163


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




164


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




165


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




166


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




167


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




Chapter 13

Commissioning Activities

ELE

CTRO

STA

TIC

PREC

IPIT

ATO

R

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

168


169


Page 1of 3


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

170


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


::

:

::

:::

:

::

:::

:

:

::

:

::

:::

:::

171


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


:

:

:

:

:

:

:

:

172


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

173


(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

CTRO

STA

TIC

PREC

IPIT

ATO

R

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.

174


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.

175


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.

176


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.


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.


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.

177


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.

178


Chapter 15

Safety Risk Assemblyfor ESP Activities

ELE

CTRO

STA

TIC

PREC

IPIT

ATO

R

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.

179


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


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


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


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


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


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


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


188


Sampling Port Arrangement Sketch No. 107

189


Sketch No. 108Sampling Port Arrangement

EN

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Chapter 17

List of Two YearsOperating Spares

190


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

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191


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]

[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

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