Erection Manual - TL Design Esp

ELECTROSTATIC PRECIPITATOR
Enviro Division
Installation &
Commissioning Manual
Improving Your Business

Is Our Business
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’.
i
Enviro Division
DIVISIONAL PROFILE
Enviro Division
Strongly believing that pollutants are inevitable but pollution is not, the Enviro Division was set up in 1980. Today,
Thermax is one of the only organizations in India having an active presence in the entire spectrum of Air Pollution
Control & Air Purification business, and is an acknowledged leader in most industrial segments. On offer is a full
range of flange-to-flange products, customized systems and value-added services. Solutions from Thermax Enviro
are present across industries and application segments, be it cement, steel, non ferrous metallurgical, power plants
and process boilers, fertilizers, tyres & tubes, paper, chemicals & petrochemicals, textiles or food & beverages - this is
just to mention a few.
Total Solutions in Air Pollution Control
+Electrostatic Precipitators - Dry & Wet
+High Efficiency Cyclones, Multiclones and Spray Cyclones
+Baghouses - Reverse Air, Pulse Jet & Insertables
+Particulate Scrubbers - Venturi, Cyclonic, Impingement Plate
+Gaseous Scrubbers - Packed Bed, Spray/Tray Towers
+Flue Gas Desulphurization (FGD) systems
+Dedusting & Fume Extraction Systems
+Coal Preparation Plants & Coal Injection Systems
+Pushing Emission Control Systems for Coke Ovens
+Retrofitting & Rebuilding
+Spares & Service
Air Purification Systems with Chemical Air Filters
The Purafil Range (for removal of corrosive, toxic and odorous gases):
+Equipment
+Media
+Instruments
The division also undertakes turnkey projects to offer complete technology in air pollution control. The division has
the expertise to handle projects from 'concept to commissioning' and tailor systems to suit the exact process
requirements. Enviro Division of Thermax is adequately equipped to offer field services for erection &
commissioning, annual maintenance contracts, repairs, retrofit & rebuild, supply of spares, trouble shooting and
customer training for its entire range of products.
ii
Electrostatic Precipitator
Contents
Installation & Commissioning Manual ELECTROSTATIC PRECIPITATOR
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
iii
Chapter 1
Introduction
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 : jagdish.dulange@thermaxindia.com
Installation & Commissioning Department
1
Chapter 2
Guidelines on Health
& Safety Measures
Guidelines on Health & Safety Measures

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.
2
ELECTROSTATIC PRECIPITATOR Installation & Commissioning Manual
14. While shifting the material from store yard / assembly point to erection site the necessary safety precautions to
be taken to avoid the fall of material, that could result in serious accident.
15. The main distribution board at all places should be with ELCB (Electric Leakage Circuit Breaker), of sufficient
capacity / rating (30mA). Also TPN (Three Phase Neutral) facility should be provided, near ESP erection &
assembly site.
16. Whenever required, use the proper extension board. Always avoid the unsafe practices of cable joints like
cable joints by twisting the cable strands and using plastic on it, etc. Always use proper sockets and plugs for
individual equipment.
17. No personnel should put their fingers inside the rotating machines, while machine is in operation.
18. Before taking trials / operating the rotating machinery, the coupling guards must be fixed at their positions. If
any foreign member / items are fixed on such rotating machinery during installation & alignment, it should be
removed before taking any trials of rotating machinery.
19. Fire extinguishers should be available (minimum 2 nos.) at site for electrical and other type of fires.
20. Safety postures should be displayed at site. Also tool-box talk should be imparted regularly at site for all
workmen. The proceedings of tool box talk should be recorded regularly.
REFER THE SAFETY RISK ASSESSMENT SHEETS ENCLOSED SEPARATELY WITH THIS MANUAL.
Thermax’s Health, Safety and Environmental policy copy is attached with this for reference.
3
4
Chapter 3
Principle of ESP
Operation
Principle of ESP Operation

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.
5
Chapter 4
Facilities
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.
6
Chapter 5
Guidelines on Storage
Facilities
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.
7
c. While unloading with crane, provide a lifting device. Lift the crates always with four slings of rope (protect
the four points of attach) and leave them in their original position without turning.
11. IS 2062 / IS 1079 steel ESP material, with factory primer painting, should not be exposed to rain or excessive
dampness for more than one month. Otherwise rust spots may appear. The material may be finish coated to
prevent rust during prolonged periods of outdoor storage in damp climates. All openings should be covered
with suitable material to protect interior surfaces from outside.
ATTENTION: Non observance of the above instructions will absolve THERMAX from every liability
concerning erection problems.
8
Chapter 6
Guidelines on Receiving &
Stacking of Material
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.
9
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.
10
Sketch No. 001 - Handling Instructions
11
Chapter 7
Standard ESP Activity
Chart
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 2. Support Structure Erection 2.2 Ground Assembly of Inlet
Casing Panels and Alignment Nozzle with GD Screen
with columns
3.1 Ground Assembly of Outlet 3. ESP Bearing installation and 3.2 Ground Assembly of Hopper
Nozzle with GD screen Alignment with baffle plates
4. ESP casing Erection,
Alignment and Welding
5.1 Erection, Alignment and 5. Erection and alignment of
welding of staircase and collecting plate floating
platform with railings channel arrangement
6. Assembly of collecting
plate panels
7.1 Erection, Alignment and 7. Erection of collecting plate 7.2 Erection, Alignment and
Welding of Inlet Nozzle panels ( by crane / by winch) Welding of Outlet Nozzle with
with GD Screen GD Screen
8. Alignment of collecting
panels
9. Positioning of top HV frame 9.2 Erection, Fit-up and welding
( by crane / by winch) of inner roof
10.1 Erection, Alignment and 10. Fixing of rigitrodes to top HV
Welding of ESP penthouse frame
11.1 Erection of hopper and its 11.Installation and Alignment of 11.2 Erection of Monorail with its
allied parts. (Fix regitrode support insulator and its structure
guide frame temporary allied parts
support inside the hopper.)
12.2 Erection of TR set base frame
12.1 Fixing of electrical items. 12. Loading of support insulators
and TR set
13.1 Fixing of the cable trays on 13.Checking the straightness of 13.2 Erection & Alignment of
ESP, for all cables (like power regitrodes in free hanging collecting plate Rapping
cables, control cables, condition and its straightening System
Feedback Cables etc.) if required
14.1 Cable laying 14. Fixing the guide frame to 14.2 Erection & Alignment of
regitrodes Regitrode Rapping System
15.1 Cable Termination 15. Alignment of regitrodes w.r.t. 15.2 Erection & Alignment of Inlet
collecting plates GD Rapping System
16.1 Cable Dressing 16. Air leak test 16.2 Thermal Insulation
Application
(After Air Leak Test)
17. Fixing of mechanical interlock system, Sign and brackets
12
For the above mentioned ESP erection activities, the requirement of Thermax's supervising engineer's site visit, to
check and guide for the ESP erection activities are indicated as below
Approx. Day of TL
Activity No.
Engineer
1 2
2 2
3 3
4
5 5
6
7
8 3
9
10
11 2
12
13 2
14
15 4
16 3
17
The above numbers of days are to be maintained, to have effective & efficient usage of Thermax engineers limited
supervision days.
The above-tabulated ESP erection activities are briefed below in two separate sections as PreErection Activities and
Erection activities and these activities are briefed below.
The standard Field Quality Plan (FQP) for ESP erection activity is enclosed with this for ready reference.
13
THERMAX LIMITED, ENVIRO DIVISION, PIMPRI, PUNE 411 018THERMAX
FIELD QUALITY PLAN FOR ESP Document No.: TL/ENV/FQP-ESP/38 Rev. 0 dtd. 15.03.06
Method
Sr. No Description Characteristics to be Method of check Extent of Acceptance standard Erection Thermax Customer
of
checked check Agency
Record
1 ESP Identification Visual 100% As per Drawing P W W

Foundation Elevation Measurement 100% As per Drawing Protocol P R W
Inspection Orientation Visual 100% As per Drawing P W W
Dimension Measurement 100% As per Drawing Protocol P R W
Installation & Commissioning Manual
2. Supporting Identification Visual 100% As per Drawing P W W

Structure, Elevation Measurement 100% As per Drawing (+/- Protocol P W W
Platforms and 3mm w.r.t. fixed
other Structural bearing column)
members Orientation Visual 100% As per Drawing P W W
Dimension Measurement 100% As per drawing within Protocol P W W
+/- 5mm tolerance
Verticality Plumb 100% Verticality1mm/mtr or Protocol P W W
Fit up Measurement 100% max. 10mm which Protocol P W W
ever is min.
Primer Touch Visual 100% As per specification P W W
3. Structural Identification Visual 100% As per Drawing P W W

Bearing Orientation Visual 100% As per Drawing P W W
Condition Visual 100% Good Condition P W W
Alignment Measurement 100% As per drawing Protocol P W W
Sprit Level Visual 100% Correct Spirit Level Protocol P W W
Water Level of Visual 100% Water level within +/-2 Protocol P W W
bearing top mm w.r.t. fixed bearing
Casing, Inlet & Identification Visual 100% As per drawing P W W

4 Outlet Nozzle, Condition & Visual 100% Good Condition P W W
Hopper, Roof Healthiness
Panel, Fit up (diagonals & Measurement 100% As per drawing Protocol P W W
14
Penthouse dimensions)
Primer touch Visual 100% As per specification P W W
Method
of
checked Agency
15
check Record
5. Collecting Plate Identification Visual 100% As per Drawing P R W
System Condition Visual 100% Good Condition P W W
Straightness at plate Use 100% Straight within +/- IR P W W
end straightness jig 3mm
Fit up Visual 100% As per Drawing P W W
Alignment Verticality Random Within +/- 4mmg IR P W W
Spacing Random As per Drawing IR P W W
6 Regitrode Identification Visual 100% As per Drawing P R W
System Condition & Visual 100% Good Condition & P W W
Healthiness Straight Pins
Straightness Straight in 100% Straight within +/- P W W
hanging 5mm
condition
Alignment Visual 100% As per Drawing P W W

Verticality 100% Within +/- 4mmg IR P W W
Spacing Random As per Drawing IR P W W
7. Carona Gap Measurement Measurement 100% As per guideline in Protocol P W W
Inspection manual
8. Collecting and Identification Visual 100% As per Drawing P W W
Rigitrode Condition Visual 100% Good Condition IR P W W
Rappers Healthiness Visual 100% Good Condition IR P W W
Fit up Visual 100% As per Drawing IR P W W
Alignment/verticality Measurement 100% As per Drawing IR P W W
9. Support & Identification Visual 100% As per Drawing IR P W W
Shaft Insulators Condition Visual 100% Good Condition IR P W W
Healthiness Visual 100% Good Condition IR P W W
10. Gas Identification Visual 100% As per Drawing P W W
Distribution Condition Visual 100% Good Condition IR P W W
Screen Healthiness Visual 100% Good Condition P W W
Alignment/verticality Measurement 100% As per Drawing IR P W W
Method
of
Record
Expansion Identification Visual 100% As per Drawing P W W
11.
Joints & Condition Dimensions Visual 100% As per Drawing P W W
Hopper Slide Healthiness Measurement 100% As per Drawing IR P W W
Gates (If Fit up Visual 100% As per Drawing P W W
applicable) Alignment Measurement 100% As per Drawing IR P W W
12. Purge Air Identification Visual 100% As per Drawing P W W

system Condition Visual 100% Good Condition P W W
Healthiness Visual 100% Good Condition IR P W W
100% As per Drawing IR P W W
Fit up Visual
Alignment Measurement 100% As per Drawing IR P W W
Functional check Visual 100% Direction of rotation & PCR P W W
Current drawn
13. Leak Testing Identification of As described 100% Air Leak Test Protocol P W W
of ESP Welding Leakages below
14. Thermal Identification Visual 100% As per Drawing IR P W W
Insulation
15. Cable laying Identification Visual 100% As per cable schedule P R W
/ Termination Cable Laying Visual 100% As per drawing P R W
and Earthing Cable Routing Visual 100% As per drawing P R W
Cable Termination Terminal points 100% As per cable schedule P R W
16. Transformer Identification Visual As per Drg. P W W

Rectifier Set Location Visual As per Drg. P W W
Electrical Tests
Die electric Strength BDV Tester 100% Should be more than PCR P R P
of Transformer Oil 50KV with 2.5mm gap
TR set Megger Tests By megger As per Pre- PCR P P W
commissioning Report
Lamp Load test Using 100w 100% Lamp should glow PCR P P W
lamps in series steadily without
flickering
Short Circuit Test By connecting 100% To rated value of PCR P P W
16
TR -ve bushing primary & secondary
to earth current
Method
of
17
Record
Open Circuit By keeping TR 100% To rated value of PCR P P W
Test IR Test -ve bushing open primary &secondary
voltage
As per electrical wiring
diagram
Functional operation Wiring check 100% PCR P P W

check and charging
panel
17 Mechanical Key Identification Visual 100% As per Drg. P W W

Interlock Location Visual 100% As per Drg. P W W
System Functional Test Operation 100% As per Drg. IR P P W
18 Rapper Control IR Test By Megger 100% As per Pre- PCR P P W

Electrical Tests
Panel Functional check 100% commissioning Report PCR P P W
19. Hopper heaters Identification Visual 100% As per Drawing P W R

(if applicable), Condition Visual 100% Good Condition P W R
Insulator heaters Healthiness Continuity Test 100% Heater coil should P W R
IR
& Hopper level not be open
switches. Fit up Measurement 100% As per Drawing P W R
IR
Functional check Measurement 100% Operation & Current PCR P W R
drawn
20. Air Load Test As per Thermax Energising TR 100% As per Pre- PCR P P W
Standard Format panels & TR sets commissioning Report
with ESP fields.
Note on Leak Test Procedure:
A) After completion of all mechanical erection activities and before starting application of insulation, leak test is to be carried out. This is
to ensure that there are no welding leakages in the ESP.
B) After ESP is boxed up, i.e. after fixing all access doors, rapper seals, insulator heaters, thermostats, hopper level probes, blank ESP inlet
and outlet either by closing the dampers (if they are available) or by fixing a blanking plate with its seal welding. Connect the Purge Air
blower directly to the penthouse. Blank all other openings e.g. hopper outlets etc. in the ESP by dummy plates.
C) Then start the Purge air blower and pressurise the ESP upto 100mmWC.
D) Pour the soap water on all site weld joints (with the help of water tube) and observe for any bubble foam. In case of weld joint leakage
bubble will be formed. Mark all such points and weld them. Repeat till no leakages are observed. During this testing keep sufficient stock
of soap water (approx. 30 liters) over penthouse.
Legends:
P -Perform; W -Witness; R- Review; IR -Inspection Report; PCR- Thermax's PreCommissioning Reports
18
Chapter 8
Guidelines on ESP
Pre-Erection Activities
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. Description Allowable Deviation

No.
1 Axial measurement in X & Y axis + /- 5mm
2 Diagonal measurement (Overall) 1mm/mts or 8mm (whichever is min.)
– In plan view
3 Diagonal meas urement 1mm/mts or 8mm (whichever is min.)
(Individual footing) – In plan view
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
19
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
Sketch No. 002 Footing Center Line Marking
Sketch No. 003
21
Sketch No. 004 Footing Center Line Marking
22
Sketch No. 005 Foundation Alignment Protocol
23
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
Sketch No. 006 Nozzle Assy Panel Fit-Up
29
Sketch No. 007 Casing Column Assembly (With Side Panel)
30
Sketch No. 008 Casing And Hopper Fit-Up Details
9 10 11
12 13
31
15
17
16
18 19
32
Sketch No. 21 Sketch No. 22
33
Sketch No. 23 Hopper Assembly Fit-Up
34
Hopper Assembly Fit-Up
35
Top High Voltage Support Frame Welding Details
Sketch No. 30
36
Chapter 9
Guidelines on ESP
Mechanical
Erection Activities
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 + /- 5mm
in X & Y axis
2 Diagonal 1mm/m or 8mm (whichever is min.)
measurement
(Individual / Overall)
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
Support Structure Alignment
Sketch No. 31
39
Structure Column Erection
Sketch No. 32
40
Structure Site Welding
Sketch No. 111
TYPICAL SITE WELDING DETAILS

FOR SUPPORT STRUCTURE / MONORAIL STRUCTURE
41
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 mm
2 Diagonal measurement 1 mm/m or 5 mm (whichever is min.)
(Individual / Overall)
3 Elevation of column top +/- 2 mm w.r.t. fixed bearing column
4 Spirit level of bearing top plate Correct spirit level
The typical check point list is as given in below table.
Bearing No. A1 B1 A2 B2 A3 B3 A4 B4
Spirit Level
Inspection
Point Water Level w.r.t.
Fixed Bearing
Mark v if inspection point is as per above tolerance guidelines and mark X if it is not as per tolerance guidelines.
Note: To ensure the correct elevation of bearing top and spirit level of bearing top plate, the needed packings
should be given only at base of support structure column and not below any bearings.
vii. Once the checkpoints (as mentioned above) are ensured, the bearings can be locked with respective
columns, by welding a thick flat piece.
ix. Once the alignment is completed, the alignment readings are to be recorded as per the enclosed format
(Sketch 35).
x. After completion of bearing alignment, further erection can be started.
HOLD POINT: FURTHER ERECTION OF ESP ON ESP BEARINGS SHOULD NOT BE DONE, UNTIL
COMPLETION AND ACCEPTANCE OF BEARING ALIGNMENT.
42
Expansion Bearing Assembly
Sketch No. 33
Sketch No. 34
43
Expansion Bearing Alignment
Sketch No. 35
44
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 Axial measurement in X & Y axis + / - 5mm
2 Diagonal measurement (Individual / Overall) 1mm/mtr or 8mm (whichever is min.)
3 Verticality / Plumb + / - 1m/mtr 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 +/- 3mm w.r.t . fixed bearing column
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
Casing Column Alignment
Sketch No. 36
46
Casing Column & Top Girder Alignment
Sketch No. 37
47
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
Staircase, Railing, Landing Fit-Up
Sketch No. 38
49
Staircase, Railing, Landing Fit-Up
50
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
Floating Channel Alignment
Sketch No. 43
52
Floating Channel Alignment
Sketch No. 44
53
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
Collecting Surface Straightening Tool
Sketch No. 45
55
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
Erection Tools
Sketch No. 46
57
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
Collecting Plate Welding Details
Sketch No. 47
Sketch No. 48
59
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
Erection Tools
Sketch No. 49
61
Lifting Frame With Panel Assy.
Sketch No. 50
62
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
Lifting Arrangement For Collecting Plate Assy.
Sketch No. 51
64
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
Collecting Plate Plumbness
Sketch No. 52
68
Collecting System Fit-Up Details
Sketch No. 53
Sketch No. 54
Sketch No. 56
Sketch No. 55
69
Sketch No. 60
Sketch No. 59
Sketch No. 61
70
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
H.V. Assembly Suspension
Sketch No.63
72
Penthouse Fit-Up Details
Sketch No. 64
73
Sketch No. 65
74
Sketch No. 66
75
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
Rigitrode System Fit-Up Details
Sketch No. 67
77
78
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
Rigitrode Lifting Frame
Sketch No. 74
80
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” 152mm or 6”
406mm i.e.16” 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.
Minimum clearance required between Regitrode pin to

Gas Passage Collecting Plate surface
Width At Top & Bottom Locations of At middle and other locations
approx. 1000mm of regitrode of regitrode
length
305 mm or 12” 148mm 136mm
406 mm or 16” 198mm 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
Collecting Plate & Rigitrode Clearances
Sketch No. 75
83
e. The above field alignment readings are to be checked and recorded, for all fields of ESP, as per table no.2.
f. Also while checking the alignment between collecting plate surface and regitrode, following clearances
hould be checked and maintained-
i. Gap between hyperbolic tube and regitrode rapper rod- it should be minimum 121mm and
ii. Gap between hyperbolic tube and tip HV frame should be minimum 121mm.
In general, the electrical clearances between any sharp high voltage corner / edge and sharp grounded
corner / edge must be minimum 180mm.
HOLD POINT: TILL COMPLETION OF FIELD ALIGNMENT, FURTHER WORK CLEARANCES SHOULD NOT
BE GIVEN
Table No. 1: Recording Position of Regitrode w.r.t. adjacent collecting plates
Corner
At Top of Field At Bottom of Field
No.
No. 1 A B C D E F A B C D E F
No. 2
No. 3
No. 4
84
Table No. 1: Format for recording collecting plate and regitrode alignment readings:
GP No. At Top of Field At Bottom of Field
1 E F E F
2
10
11
12
13
14
15
16
17
18
Note: The above format of alignment reading recording is for 18 gas passages. However, in case of more gas
passage, similar format can be made and used.
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
Casing Baffle Arrangement
Sketch No. 76
87
Sketch No. 77
88
Sketch No. 78
89
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
Inlet & Outlet Nozzle Assy. Fit-Up
Sketch No. 79
91
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
Sketch No. 80
93
94
Inlet & Outlet Nozzle Rapping Fit-Up
Sketch No. 83
95
Inlet & Outlet Nozzle Rapping Fit-Up
Sketch No. 84
96
G. D. Screen Assy. Fit-Up
Sketch No. 85
97
G. D. Screen Assy. Fit-Up
Sketch No. 89
Sketch No. 88
Sketch No. 90
98
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
Hopper Baffle Arrangement
Sketch No. 91
100
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
Hopper Baffle Arrangement
Sketch No. 92
102
Casing And Hopper Fit-Up Details
Sketch No. 93
103
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
Monorail Structure Assembly
Sketch No. 94
105
Structure Site Welding
Sketch No. 111
TYPICAL SITE WELDING DETAILS

FOR SUPPORT STRUCTURE / MONORAIL STRUCTURE
106
1) TRANSFORMER RECTIFIER MUST BE IN A LEVEL,
THE HIGH VOLTAGE CONDUIT MUST BE IN CENTER
OF H.V.DUCT.
Sketch No. 95
2) JUMPERS MUST BE USED AT ALL FLG. AND HIGH

VOLTAGE BOLTED CONNECTION.
3) ALL INSULATORS MUST BE PROTECTED FROM

WELD SPLATTER.
4) ALL ELECTRICAL BUS MUST BE DISCONNECTED

COMPLETLY WHENEVER ANY WELDING IS BEING
DONE INSIDE THE PRECIPITATOR CHAMBER OR PENT
HOUSE COMPARTMENT.
High Voltage Assy. With T/R
5) REQUIRED SHIMS/PACKING STRIPS TO BE

PROVIDED AT SITE.
6) CHANNELS SHOULD BE SITE WELDED TO

PENTHOUSE STIFFENERS TO FORM A BOXED
CHANNEL BELOW T/R SET. REQUIRED RAW
MATERIAL IS CALLED IN PENTHOUSE ASSEMBLY BOM.
7) ARRANGE THE LOCATION OF T/R SET AND H.V.

ASSLY ON PENTHOUSE ROOF, SO THAT ALL T/R
SETS CAN BE HANDLED WITH MONORAIL STRUCTURE
IN POSITION IN SHORT, ERECTION ENGINEER
SHOULD REFER MONORAIL STRUCURE ASSLY
DRAWING, BEFORE ERECTION OF H.V. ASSLY AND T/R
SETS.
107
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
High Voltage Assy. With T/R
Sketch No. 96
109
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
Sketch No. 98
Sketch No. 99
111
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
Sketch No. 67
113
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
Sketch No. 101
Sketch No. 102
115
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
Sketch No. 79
117
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
Warning Sign Locations
Sketch No. 103
119
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 Above Access Door
Warning Sign for Hopper Access Door Above Access Door
Warning Sign for Duct Access Door Above Access Door
Warning Sign for High Access Door On TR Door
Thermax Monogram On ESP Top
Along with above warning signboards on ESP access doors, two more warning sign boards are to be
displayed in the plant control room. These warning signboards are attached with this as sketch no. 105 and
106. These are related to stoppage of ESP in case of higher CO level in process. Such warning boards should
be displayed near the ESP, ID fan and in plant control room, ESP control room. Also such boards should be
displayed in the local language which local people can understand.
+Mechanical Interlock System
The mechanical door interlocks are provided to ensure proper lock out of electrical system and de energisation of
HV transformer rectifier sets, before entering inside the ESP.
The system comprises the set of castle key & locks, such that unless TR control panel is switched off and transformer
rectifier set’s grounding switch is operated to earth position, the keys for various access doors are not available for
opening the doors.
These interlocks (i.e. keys / locks) are fixed at following locations –
a) On all access doors like casing, inlet nozzle, outlet nozzle, hopper, and penthouse.
b) On TR set in earth switch position and live position.
c) On TR set control Panel.
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
DOOR INTERLOCK DIAGRAM
B B B B
TRANSFER BLOCK - B1 & B2 B B B B
(KEY EXCHANGE ASSEMBLY)
B B DOOR INTERLOCK
BOX MOUNTED IN
CONTROL ROOM
X1 X2
TRANSFER BLOCK - C
X1 X2 X
TRANSFER BLOCK ‘A’ G3 G2 G1
G3 G2 G1 GROUNDING SWITCH
BW BW BW EARTH POSITION
LOCK ON GROUNDING
D3 D2 D1 SWITCH ENCLOSURE
BE BE BE
MOUNTING ON TRCC PANEL

D3 D2 D1 (LOCK FOR HT INTERLOCK)
BW BW BW
TRCC3 TRCC2 TRCC1
5A ‘NO’ CONTACT
NOTES :-
1) LOCK SHOWN IN NORMAL OPERATING POSITION.
2) ABBREVIATIONS :-
BE - BOLT EXTENDED KEY RELEASED.
BW - BOLT WITHDRAWN KEY RETAINED.
- LOCK WITH KEY
- LOCK WITHOUT KEY
3) 5A ‘NO’ CONTACT TO BE PROVIDED FOR D1, D2 & D3 SOCKET TO BE MOUNTED ON TRCC PANEL.
+Operational Philosophy :
For accessibility to ESP internals through access door, following sequence to be followed.
121
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 D1,D2,D3 3 nos.
with key & electrical switch)
2 Ground switch lock (For changing position & 1,D2,D3 3 nos.
interlock with TRCC on/off)(Lock without key)
3 Ground switch lock (For locking the grounding 1,G2,G3 3 nos.
switch to ESP earth position) (with key)
4 Transfer block assembly – A consists of 3 -nos. 1,G2 ,G3 & 1 set.
lock without key & 1 no. master lock (`X’) with key
X
5 Key exchange box (Transfer block assembly – C) 1,X2 & X 1 set.

consist of 2 nos. lock with key (‘X1’,’X2’) & 1no.
master lock without key (‘X’)
6 Key exchange box (Transfer block assembly– B1& B2) 1=7 nos. 1 set.
Consist of 7 nos. & 4 nos. access door locks B2=4 nos.
with key each & 1 no. master lock (`X1’ & ‘X2’ X1=1 no.
respectively) without key X2=1 no.
7 Chain type door locks with out key for access doors B 11 Nos.
(On ESP)
122
CO Explosion Warning Sign For Kiln
Sketch No. 105
WARNING
WHEN THE KILN IS STOPPED OR KEPT UNDER HOLD, ENSURE THAT THE
ESP INLET DAMPER IS CLOSED WITHIN 2 MIN. WITH ABC CAP OPEN.
AND ESP I.D. FAN SWITCHED OFF.
THERE AFTER ESP PURGE AIR FAN TO BE SWITCHED OFF WITHIN 5 MIN.
ALLOWABLE `CO' IN FLUE GAS = 1 % MAX.

BE CAREFUL ABOUT EXPLOSIONS DUE TO `CO'.
CONTROL & TUNE YOUR EQUIPMENT OPERATION.
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
THERMAX LIMITED
ENVIRO DIVISION, PUNE, INDIA
CUSTOMER SHOULD DISPLAY THE INSTRUCTIONS IN LOCAL LANGUAGE ALSO.
123
Typ. Warning Sign
Sketch No. 104
? WARNING
USE
EYE AND SKIN
HEAD AND NOSE
PROTECTION
HIGH VOLTAGE.
ENSURE THAT TR SETS ARE SWITCHED OFF
AND EARTHING SWITCHES ARE GROUNDED
BEFORE ENTERING ANY H.V. AREA.
ATTACH GROUNDING HOOKS ON ALL H.V.
COMPONENTS BEFORE ENTRY.
DO NOT REMOVE HOOKS UNTIL WORK IS
COMPLETED.
FOLLOW THE MECHANICAL KEY INTERLOCK
SEQUENCE, ENSURE THAT KEY INTERLOCK
IS NOT TAMPERED.
ENSURE FAN IS STOPPED

HOOK SAFETY CHAIN.
OPEN AND PADLOCK
ACCESS DOOR
KNOCK OVERHEAD DUST.

PROVIDE ADEQUATE
LIGHT & VENTILATION
124
CO Explosion Warning Sign For Boiler
Sketch No. 106
WARNING
WHEN THE BOILER IS STOPPED, ENSURE THAT THE
I.D. FAN IS SWITCHED OFF AFTER 15 MIN. AND THEN
ESP PURGE AIR FAN SHOULD BE SWITCHED OFF AFTER 10 MIN.
ALLOWABLE `CO' IN FLUE GAS = 1 % MAX.

BE CAREFUL ABOUT EXPLOSIONS DUE TO `CO'.
CONTROL & TUNE YOUR EQUIPMENT OPERATION.
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
THERMAX LIMITED
ENVIRO DIVISION, PUNE, INDIA
CUSTOMER SHOULD DISPLAY THE INSTRUCTIONS IN LOCAL LANGUAGE ALSO.
125
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
Insulation Arrangement
Sketch No. 110-A

DESCRIPTION
D.U.NO.
127
Sketch No. 110-B
128
Sketch No. 110-C
129
Chapter 10
Electrical Activities
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.
1
Transformer
2 Rectifier Unit
(Representative)
Control 3
Panel
(Representative)
4
5 To Remote On/Off
6 To Remote 4-20 mA indication

To Remote Alarm/Trip indication, HT On/Off
7
indications (Optional)
139
Refer following Sl. Nos. for above circled numberings, in detail.
Sl. No Cable Details Layout
Cable for Power Connections: PVC Insulated, Power cables should not to be mixed with any
650 / 1100 V Grade, Aluminum Conductor, control cable (Sr.No. 3, 4 & 5)
1.
Armoured cable. (Size & details as per Project
Rating)
Cable for Primary Voltage Feedback : 2C or Feedback cables should not to be mixed /
3C2.5 sq. mm., PVC Insulated 650 / 1100 V bunched with Cables for Secondary Current &
2. Grade, Copper Conductor, Armoured Voltage feedback & Cable for Alarm &
Control Cable Annunciation, i.e. Cable No. 3 & 4. This can
be bunched with Power cable( Sr.No.1)
Cable for Secondary Current & Voltage These cables to be laid separately and not to
Feedback : 4C-1.5 sq. mm., PVC Insulated be mixed with power cables (Sr.No.1) or
3. 650 / 1100 V Grade, Copper Conductor, Primary Voltage Feedback cable (Sr.No. 2) or
Overall shielded with minimum 80% shielding any other cable having potential higher than
Armoured Control Cable 30 V.
Cable for Alarm & Annunciation : To be laid separately and not to be bunched
10C-2.5 sq. mm., PVC Insulated 650 / 1100 with Power Cable (Sr.No.1) or Primary Voltage
4. V Grade, Copper Conductor, Armoured Feedback Cable (Sr.No.2) or Cable for
Control Cable Secondary Current & Voltage (Sr.No. 3) or any
other cable having potential higher than 50 V
Cable for Remote On / Off (Optional) : These cables should not to be mixed /
3C-1.5 or 2.5 sq. mm., PVC Insulated 650 / bunched with any power cable &
5.
1100 V Grade, Copper Conductor, instrumentation cable.
Armoured Control Cable
Cable for Remote 4-20 mA Feedback These cables should not to be mixed /
Indication (Optional) : bunched with any power cables / control
4C-1.5 sq. mm., PVC Insulated 650 / 1100 V cable having potential higher than 30 V
6.
Grade, Copper Conductor, Overall shielded
with minimum 80% shielding Armoured
Control Cable.
Cable for Remote Alarm / Trip indication, HT Not to be mixed / bunched with any power
On / Off indications (Optional) *C-2.5 sq. cable & instrumentation cable
mm., PVC Insulated 650 / 1100 V Grade,
7.
Copper Conductor, Armoured Control Cable
(* No. of cores as required, Pl. refer the project
specific schematic drawing)
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
Figure 1
≥300 mm
=30mm =100mm
Metal Cable Tray
Control Cables:
Power Cables: Signal Cables:
(Typically 230 V 110 V)
(Typically 415 V / 230 V) (Typically 24 V / 4-20 mA,
Relay Supply
Control Panel Supply Instrumentation cable)
Contactor Supply
Fan Motors Supply Feedback Cables
Pump Motors Supply Alarm Cables
Figure 2
Unshielded portion of shielded wire

Shielded Wire
(Typically 50mm)
Unused core of cable shall be

kept opened & insulated
142
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.
Sl. No. Equipment GI Strip / Wire Size

1 T/R Set 50 x 6 MM. STRIP
2 Earth Grid (along ESP Column) 50 x 6 MM. STRIP
3 Earth Grid (On ESP Roof) 50 x 6 MM. STRIP
4 TRCC Panel 50 x 6 MM. STRIP
5 Auxiliary Control Panel 50 x 6 MM. STRIP
6 Micro Tapper Panel 50 x 6 MM. STRIP
7 Earth Switch 50 x 6 MM. STRIP
8 Hoppers 25 x 3 MM. STRIP
9 Grid for Upper / Lower Platform & at Hopper Level Platform 25 x 3 MM. STRIP
10 Rapper Distribution Panel 25 x 3 MM. STRIP
11 Insulator Heater JB 2 X 8 SWG WIRE
12 Level Controller JB 2 X 8 SWG WIRE
13 Hopper Heater JB 2 X 8 SWG WIRE
14 Control Junction Boxes 2 X 8 SWG WIRE
15 Rapper Coils 2 X 8 SWG WIRE
16 Purge Air Blower 2 X 8 SWG WIRE
17 Rotary Air Lock Valve 2 X 8 SWG WIRE
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
Earthing Arrangement of Control Panel And TR Set For ESP
Sketch No. 113
145
Hook-Up For Insulator Heater
Sketch No. 114
146
Hook-Up For Level Switch
Sketch No. 115
147
Hook-Up For Temp. Element
Sketch No. 116
148
Hook-Up For Temp. Element
Sketch No. 117
149
Hook-Up For Thermostat
Sketch No. 118
150
Hook-Up For Zero Speed Switch
Sketch No. 119
151
Chapter 11
ESP Pre Commissioning
Checklists
The pre commissioning checklists are attached, here after. All checkpoints given in this checklist are to be checked
jointly with Thermax's ESP supervisor, Customer' ESP supervisor and contractor. The report on this checklist should be
signed after completion of the checkpoints.
The ESP pre commissioning activities should not be carried out unless until attached checklist is completed and
signed off jointly.
152
ESP's Mechanical Completion Check Lists
Name of Customer:
153
Plant / Site Location:
Customer PO No.:
Thermax OC No.:
Name of Thermax Representative:
Sl. Completion Date Checked & Witnessed

Check Point Description
No. by
Field 1 Field 2 Field 3 THERMAX Customer
Civil Foundation
1 ESP foundation inspection and its acceptance protocol (axial & diagonal measurements as per drawing).
ESP Support Structure

ESP support structure erection as per drawing and its alignment (i.e. plumb, axial & diagonal measurements) its
1 acceptance protocol.
ESP BEARING
Bearing alignment inspection protocol [level (spirit & water), axial & diagonal measurements w.r.t. fixed bearing as per
1 bearing layout drawing] and its acceptance protocol.
Casing
Erection of ESP casing panel & column, top & bottom girder as per drawing w.r.t. ESP centerline and its inspection
1 protocol (for plumb, axial & diagonal measurements).
Inspection of weld joints. Kerosene leak test of all weld joints.. All weld joints should be free from for left out welding /
2
welding defects like blow holes, welding cracks etc.
Removal all temporary supports provided for casing erection / welding purpose, after ESP alignment and before ESP box
3 up.
Inlet Nozzle with Perforated Sheets
1 Inspection of inlet nozzle assembly & its installation with perforated sheets as per drawing.
2
welding defects like blow holes, welding cracks etc.
3 Alignment of inlet nozzle inlet flange (plumbness and diagonal).

Outlet Nozzle with Perforated Sheets
1 Inspection of outlet nozzle assembly & its installation with perforated sheets as per drawing.
2 welding defects like blow holes, welding cracks etc.
3 Alignment of outlet nozzle inlet flange (plumbness and diagonal).
Sl. Completion Date Checked & Witnessed by
No. Field 1 Field 2 Field 3 THERMAX Customer
Hopper with its baffle plates and other accessories
1 Erection of hopper as per drawing with hopper baffle plates and inspection door.
2 welding defects like blow holes, welding cracks etc.
3 Inspection of hopper outlet flange/s for its spirit / water level.
4 Installation of hopper level probe as per drawing.
5 Installation of hopper heater thermostat (as per drawing), if applicable.
Installation of hopper vibrators (as per drawing), if applicable.

6
Installation of hopper heating pad, (as per drawing), if applicable.

7
Installation of Rotary Air Lock Valve and Slide Gate below hopper (as per drawing), if applicable. Check the flange to
8
flange sealing.
Collecting Plate Assembly
1 Inspection of floating channel arrangement for axial, diagonal measurements and water level.
2 Check all collecting plates are free from bows / local deformations.
3 Inspection of collecting plate assemblies for its diagonals and other measurement, as per drawing.
4 Check the tightness of fasteners used for collecting plates assemblies and its welding before collecting plate erection.
Check the straightness & plumb of installed collecting plate, in its free hanging condition. All collecting plates should be
5 straight in the tolerance of +/- 5 mm, either side.
6 Welding of all fasteners (Nut to bolt welding) used for collecting plates / its assemblies after alignment.
Regitrodes with its allied parts
Inspection of top HV frame erection and its alignment (level & positioning w.r.t. adjacent collecting plate rows). Ensure that
1
the regitrode rows (in gas flow direction) are in the mid-way of the adjacent collecting plate rows.
2 Check the straightness of all installed regitrodes, in its free hanging condition. All regitrodes must be straight.
Check the gap between collecting plate and regitrode, using GO / NO GO type gauge. All temporary locking / supports of
3 regitrode frame must be removed before gap checking. While checking the gap, top HV frame should be in free hanging
condition. Record all the deviations of this inspection and attach the records with this checklist.
4 Welding of all fasteners (Nut to bolt welding) used for regitrodes and its allied parts, after gap checking.
ESP Baffle Plates
1 Check installation of casing baffle plates as per drawing.
2 All baffle plate shall be seal welded with casing panel. No gap between baffle plate and casing side panel is allowed.
Support Insulator
1 Installation of support insulator installation and its allied parts.
2 Alignment of top HV frame, after support insulator loading.
154
Collecting Plate Rapping System
1 Alignment (verticality / plumb) of rapper rods.
No.
155
Field 1 Field 2 Field 3 THERMAX Customer
2 Exposure of rapper plunger outside the rapper coil. The plunger should be projected 38mm (ONLY)
outside the coil, for effective rapping.
3 Alignment of rapper coils. All rapper coils must be in correct vertical position (plumb).
4 Grounding of the rapper rods.
5 Sealing of rapper rods, using hypalon boot and clamps.
Discharge Electrode Rapping System
1 Alignment (verticality / plumb) of regitrode rapper rod and shaft insulators.

3 Exposure of rapper plunger outside the rapper coil. The plunger should be projected 38mm
(ONLY) outside the coil, for effective rapping.
4 Level of rapper coils. All rapper coils must be in correct vertical position (plumb).

Inlet Gas Distribution Screen Rapping System
1. Alignment (verticality / plumb) of rapper rods and double tapered rapper rods.
2. Exposure of rapper plunger outside the rapper coil. The plunger should be projected 38mm (ONLY)
outside the coil, for effective rapping.
Mechanical Interlock Systems
1 Check correct interlocks are fixed on following locations -
a. TR set (Grounding Switch & Live Position Switch).
b. TRCC Panel.
c. Casing Access Doors.
d. Hopper Access Doors.
e. Penthouse Access Doors.
f. Inlet & Outlet Nozzle Access Doors.
2 Check Functioning of interlock system with individual keys & transfer blocks.
Penthouse with insulation
1 Installation of penthouse panels as per drawing and its seal welding.
2 Kerosene leak test of all seal weld joints.
3 Thermal insulation of penthouse top plate insulation from inside. The thermal insulation should not touch
to the shaft insulator. Proper cutting to be ensured around the shaft insulator.
No. Field 1 Field 2 Field 3 THERMAX Customer
Purge Air System
1 Check the location of purge air system, as per drawing. While installing the purge air system, ensure that
there is sufficient space available around the filter unit / blower / electric motor, for maintenance purpose.
2 Fixing of anti vibration pads and flexible connection(at inlet & outlet of blower) for purge air blower.
Monorail Structure with lifting equip.
1 1
Monorail installation, alignment and welding as per drawing
2 Welding of stoppers at both free ends of the monorail beam.
3 Installation of lifting equipment (Chain Pulley Block) with trolley.
4 Free travel of the trolley with chain block.
Transformer Rectifier Set with HV Duct
Check the TR set oil BDV value. If BDV value is less than 50 kV, the TR oil re-filtration is to be bone, till
1
BDV value reaches more than 50 kV. This is to be done before TR set is erected on ESP top.
2. Erection of TR set and its HV ducting as per drawing.

3 Oil level in the TR set.
4 Operation of TR set earthing switch.
156
Chapter 12
Pre Commissioning
Activities
Following are the pre commissioning activities, to be carried out in the sequence / parallel mentioned below.
Pre Commissioning Activities
+ Checking of cable continuity + Gas Distribution Test + Checking of TR set oil BDV
/megger for all power / control / value.
feedback cables
Checking of earth resistance
+ + Checking of TR panel wiring, as + Operational checking of hopper
per drawing heaters w.r.t. Thermostat setting
+ Checking of RDP panel + Checking of TR panelfor lamp + Operational checking of

(Resistance / Continuity checking) load Insulator heaters w.r.t. Thermostat
as per designed groups. setting
+ Checking of MTP panel and its + Checking of TR set for Open + Operational checking /
lamp load testing Circuit & Short Circuit test calibration of hopper level
controllers / Hopper Vibrators (if
applicable)
+ Checking of MTP panel with all +
Air load test + Operational checking of Purge
rappers and rapper lift checking Air Blower
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
THERMAX LTD
ENVIRO DIVISION
PRECOMMISSIONING REPORT (ESP)
158
Gas Distribution Report Format
Format: T-EPD-SR-F-023
Customer:
Plant Location:
Date: Time: From Hrs To Hrs
Gas Passa ge
Approx. Height 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18
from bottom
8.5 m
7.5 m
6.5 m
5.5 m
4.5 m
3.5 m
Inspection Door Side

2.5m
1.5 m
0.5 m
AVERAGE VELOCITY (V avg) m/sec

1.15 times V avg m/sec
1.40 times V avg m/sec
Total Velocity Readings Nos.
No. of readings within 1.15 times V avg Nos. In %
No. of readings within 1.40 times V avg Nos. In %
Remarks: 1. Indicate the casing inspection door side in the report.

2. The gas distribution test is conducted at field 1 outlet side.
3. The ID fan current, damper positioning and Fan Speed is to be noted in the report.
Notes:
1 During test - The ID Fan current was Amps and ID fan inlet damper opening was %
2 During test - The FD Fan current was Amps and FD fan inlet damper opening was %
The above format is for 18 gas passage with 9m collecting plate height. Similar format should be modified for more number of gas passage and for higher collecting
3
plates.
For Thermax Ltd For Customer

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
PRECOMMISSIONING REPORT
Page 1of 7
Client:- Application:-
Client’s PO No.:- Thermax’s OC No:-
Format: T-EPD-SR-F-023 Rev.: 1
T/R SETS & TRCC DETAILS
Make Serial No.

Field No. Remark
TR Set TRCC TR Set TRCC Controller
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 side
bushings separately.
2. For LT to Earth 1000V megger to be used and for HT to Earth 500V megger to be used.
3. Connect the megger between Primary to Earth, Secondary to Earth and Primary to Secondary.
4. The minimum value of insulation resistance should be as follows:
MINIMUM
DESCRIPTION REQUIRED (IN MO) FIELD 1 FIELD 2 FIELD 3
Primary To Earth (LT To Earth) 50
Primary To Secondary (LT To 500
HT)
Secondary To Earth ( HT To 100
Earth)
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 3

Average
Date:
Name:
Sign:
COMPANY: THERMAX CUSTOMER CONSULTANT
161
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 3

Test 1
Test 2
Remarks Controller Healthy / Controller Healthy / Not Controller Healthy / Not
Not Healthy Healthy Healthy
Note:-For healthy lamp load test, both the lamps should glow steadily.
Date:
Name:
Sign:
162
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. Primary Primary Secondary Sec. Current Remarks

Voltage (V) Current (A) Voltage (kV) Set Pt. (mA)
Field 1
Field 2
Field 3
Note: - For healthy TR set, Primary Current values should not exceed 6 amps for ratings upto 500mA
and 10 Amps for ratings upto 1500mA.
In case of excess primary current, the TR sets should be switched off and TR sets are to be
checked for abnormalities.
T/R SETS: SHORT CIRCUIT TEST
1. Connect the TR set HT bushing to Earth either by connecting a separate wire or by operating
grounding switch handle to earth position.
2. The following test is to be carried out through TRCC Panel only.
3. During this test Is setting should be kept at 25% of rated secondary current and shall be
increased gradually to 50%, 75% and 100%.
SHORT CIRCUIT TEST RESULTS
Pass & Field Sec. Current Primary Primary Secondary Secondary Remarks
No. (Is) set Point Voltage (V) Current (A) Voltage (kV) Current (mA)
Field 1
Field 2
Field 3
Note: -
1. TR Controller shall not sense any spark during this test.
2. mA setting and mA actual and mA meter readings should be within±5% t
Date:
Name:
Sign:
163
Page 4of 7
TESTING OF EARTHING STATIONS
Earth Earth Resistance (In mO)

Station No.
1
2
3
4
5
6
7
8
9
10
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 (MO)

1
2
3
4
5
6
7
8
9
10
Date:
Name:
Sign:
164
Page 5of 7
T/R SETS: AIR LOAD TEST

This test is to be carried out through TRCC panel only.
MA Field 1 Field 2
Set P rimary S econdary Spark P rimary S econdary Spark
Point Voltage Current Voltage Current Rate Voltage Current Voltage Current Rate
(V) (A) (kV) (mA) (V) (A) (kV) (mA)
MA Field 3
Set P rimary S econdary Spark
Point Voltage Current Voltage Current Rate
(V) (A) (kV) (mA)
Date:
Name:
Sign:
165
Page 6of 7
RAPPING SYSTEM - ELECTRICAL TEST REPORT
Micro–Tapper Panel Sl. No.: Matrix Size :
TEST RESULTS
Rapper Group Rapper Forward Reverse Row to Col. Lift Actual Remarks
No. No. for CE / Meggaring Meggaring Earth to Setting Lift
EE / +ve to Row / +ve to Col Earth (Inches) (Inches)
PDPL -ve to Col. -ve to Row
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
Date:
Name:
Sign:
166
Page 7of 7
Rapper Group Rapper Forward Reverse Row to Col. Lift Actual Remarks
No. No. for CE / Meggaring Meggaring Earth to Setting Lift
EE / +ve to Row / +ve to Col Earth (Inches) (Inches)
PDPL -ve to Col. -ve to Row
33
34
35
36
37
38
39
40
41
42
43
44
45
46
47
48
49
50
51
52
53
54
55
56
57
58
59
60
61
62
63
64
Date:
Name:
Sign:
167
Chapter 13
Commissioning
Activities
Following is the sequence for ESP 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.
168
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
P arameters UoM Inlet Outlet

Des ign Ac tual Des ign Ac tual
Gas Flow AM3 / Hr
Inlet Dust load gm / NM3 NA NA

3
Out let Dust mg / NM NA NA
concentration
Temperature °C
7. Load on customer’s equipment :

against rated load
8. TR set Operational Readings :
Field No. Primary S ide S ec ondary Side Sparks

per min.
Voltage in Current in amps Voltage in kV Current in mA
Volts
Field 1
Field 2
Field 3
169
Page 2of 3
9. Microtapper Panel
:
i) Make and Sl. No. :
ii) Model :
iii) Parameter Setting :
Group 01 02 03 04 05 06 07 08 09 10 11 12
No.
RTT in
min.
Lift in
inch.
10. Dust Handling System (Below Hopper) :
A. Scope : Thermax / Customer

B. Pneumatic Conveying System :
i) Make and Model :

ii) Performance
:
C. Screw Conveyor :
i) Make and Model :

ii) Drive make and Model :
iii) Performance :
iv) Current Drawn in amps :
D. Rotary Airlock Valve :
i) Make and Model :

ii) Drive make and model :
iii) Performance :
E. Compressor :
i) Make and Model :

ii) Drive make and model :
iii) Performance :
11. Power Supply (Customer’s scope) :
i) Supply Voltage :
ii) Fluctuation, if any :
12. Control Room :
i) Air Conditioned :
ii) Pressurised :
iii) Dusty / Clean :
170
Page 3of 3
13. Thermal Insulation:
14. Purging System :
i) Blower make and model :

ii) Heater make and model :
iii) Motor make and model :
iv) Performance :
v) Current Drawn in amps :
15. Insulator Heater :
1) Performance :
2) Thermostat Setting :
3) Current Drawn in amps. :
16. Hopper Heater & Level Controller:
Field No. Heater Heater Current Thermostat Level Controller

Performance Drawn in amps. Setting in °C Performance
Field 1
Field 2
Field 3
17. Name of the person & signature :

carrying out Commissioning trials.

witnessing Commissioning trials.

handing over unit

taking over unit.
Enclosure(s) :
171
THERMAX LTD
ENVIRO DIVISION
PMT Complex, Behind PCMC Building
Mumbai-Pune Road, Pimpri
PUNE 411 003
ACCEPTANCE REPORT
Page 1 of 2
Format: T-EPD-SR-F-029 Rev 0
This acceptance report is between
The customer_________________________________________________________________________________
And
Thermax Limited,
Enviro Division,
Pune
(A) Regarding the supply, erection of ESP vide Customer’s Order
no.___________________________ and Thermax’s OC no. _____________ and commissioning
of Electrostatic Precipitator
(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 been
carried out.
(D) The supply, erection & commissioning completed as per the milestones listed below :-
Completion Date
Delivery of equipment is completed
Erection & pre–commissioning tests completed
Commissioning
Trial run completed
Temporary taking over
Warrantee starts
(E)
Participant Name Company Date Signature
1.
2.
3.
172
THERMAX LTD
ENVIRO DIVISION
PMT Complex, Behind PCMC Building
Mumbai-Pune Road, Pimpri
PUNE 411 003
ACCEPTANCE REPORT
Page 2 of 2
(F) Corrective Work:
Sl. Scheduled Date

Natureof Work R esponsibility
No. of Completion
Participant Name Company Date Signature

1.
2.
3.
173
Chapter 14
Precautions
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
1.
should be mounted in bottom 1/3rd of the hopper on opposite sides.
2. RAV of size 400 should be provided.
3. RAV speed should be 10 to 15 RPM to increase the dust discharge efficiency.
4. RTD sensor & transmitter 1 for each hopper to be provided
5. Hoppers shall be provided with SS 304 2D / 3D finish liners for bottom 1/3rd portion.
The bypass chute shall be provided with blind flange. (Minimum size 400-mm dia.) except for
6.
trough hoppers.
7. Hoppers shall have large poking holes of minimum 100 NB size to avoid dust bridging
176
Following interlocks are incorporated in the design, and to be ensured at site.
Equipment / Instrument
Sr. No. Signal Action
Parameter
Alarm & Indication in ACP. Trip respective TR SET.
Rotary Air Lock valves provided
Trip signal is taken from zero Signal to DCS
below I&II Field HoppersTrip
1. speed switch(This zero speed
switch is fixed near Rotary Air Lock
Valve Driven end )
Rotary Air Lock valves - Over load Alarm & Indication in ACP. Trip respective TR SET.
2.
relay Trip. Signal to DCS
If RAV faults persist for 2 hrs. Potential free contacts of Trip relay Trip Boiler.
will be provided in Signal to DCS
3.
ACP for alarm & indication + tripp
signal to Boiler.
Dust conveying system shall be Potential free contact for tripping All TR SETS, all RAV
4. ON all the time. If dust conveying the all TR SET, all RAV. shall trip.
system trip/stopped.
Hopper Heater (provided to keep Alarm &Indication in ACP. Trip Hopper heater.
the ash hoppers hot to increase Signal to DCS
5. the flowability of ash- Normally,
used to be started before 4 hrs of
Boiler start up) Temperature High.
RTD to be mounted in each Alarm & indication in ACP, Trip respective TR SET.
6. Hopper, with TIC in ACP. Hopper Potential free contact for tripping Signal to DCS.
Temperature Very High the Boiler. Trip Boiler.
Transformer Sets (T.R.SET) Trip. Alarm &Indication in TRCC. Signal to DCS
7.
Potential free contact to DCS.
Hopper Level High.(Level probe Alarm &Indication in ACP. Trip respective TR SET.
provided at about 60%of total Immediately Trip the Signal to DCS
8. hopper height distance below the corresponding Transformer sets.
collecting plates ) Potential free contact in ACP for
DCS signal.
Hopper Level High alarm persists Potential free contacts in ACP to Trip Boiler.
9. for 1 hr wire the same for Boiler Signal to DCS
Tripping/Stopping.
In case Inlet temp. Sensed by TE Alarm & Indication in ACP, Trip respective TR
increases above set point. potential free contact for DCS Sets. Signal to DCS
10.
TE to be mounted in the inlet duct signal
of ESP.
177
I D FAN interlock. Potential free contacts in ACP, Trip I D FAN.

If RAV or Screw conveyor stopped Alarm & Indication in ACP Signal to DCS.
11.
/ tripped. &potential free contact to trip the
ID FAN.
Rapping system shall be ON all ID Fan ON potential free contact

the when ID FAN is running to MTP.
12.
irrespective of ESP is charged or
not.
Purge Air System Interlock If Purge air system is not working Audio Visual Alarm
13.
then trip the T/R sets.
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 Assembly
for ESP Activities
Safety Risk Assembly for ESP Activities

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
RISK ASSESSMENT FOR ESP ( ELECTROSTATIC PRECIPITATOR) INSTALLATION
180
Safety Risk Assessment Document (ESP) No.: TL/ENV/ESP/Safety/001 Rev 0
Sl.
Activities Hazards Safety Precaution Responsibility
No.
a) Fall / slip of objects due to inadequate a) Use of PPEs like safety shoes, Hand gloves, Safety helmet Contractor & Customer
handling facilities b) Use of catagorised skilled personal Contractor & Customer
c) Safety introduction to all workmen & supervisors. The emergency contact
nos.,like Fire / Ambulance / Nearest Hospital / Security are to be made Thermax Engg.
available at all locations like site office / ground assembly area / erection
1 Unloading of area and also with site engineers / contractor supervisors
materials
b) Damages to the material due to not a) Safety instructions are to be followed during unloading of material. Thermax Thermax HO
following the safety instructions HO to send the safety instruction / risk assessment to sites well in advance.
b) Special safety / unloading instruction for collecting plates / emitter electrodes Thermax HO
/ support & shaft insulator / GD screens are to be circulated in advance.
c) Unloading instructions to be sent to site alongwith material. Thermax HO
c) Use of inadequate / wrong / undersize a) Use of correct size tools / correct capacity equipment for unloading the Contractor & Customer
material handling tools / equipment material; b)
a) Caught in between finger / foot injuries a) Use of PPEs; b)Follow safe material handling procedure; c) Use of proper Contractor & Customer
2 Storage / stacking material handling tools & tackles. / Use of catogarised skilled manpower /
of materials Use of correct tools / tackles / equipment for stacking the material
b) Fall of ESP material due to improper Use of suitable wooden sleepers, supports to avoid fall of stacked material. / Contractor & Customer
stacking, resulting in to accidents and Provide sufficient cover like temporary shed / tarpaulin to avoid the damages
damage to material to the material due to dust / rain.
c) Gas Storage facility LPG / Acetylene gas storage facility Contractor & Customer
All lifting material to be tested for their capacity before taking them in to use. Contractor & Customer
a) Breakage of chain sling / wire rope
Test certificate to be obtained from competent person. This is required as
& manila rope
per factories act 1948.
Shifting of materials
3 to site (Manual &
mechanical material c) Breakage of chain sling / wire rope All lifting material / tools / tackles shall be checked periodically, for any Contractor & Customer
handling equipment) & manila rope defects those arises during its use and stop its using if any defects found
i) Verification of loading point of hydra / chain pulley block / test certificates Contractor & Customer
b) Overloading of equipment during of wire ropes
lifting
ii) Identification / marking of weight on the job being lifted Contractor & Customer
Sl.
No.
c) Inadequate lift hook position ( Vertical Proper lifting hooks are to be considered during design stage and Contractor & Customer
& horizontal lifting) same to be provided during fabrication stage. (Check the marking on
the component in place
Shifting of materials of lugs.)
3 to site (Manual &

mechanical material f) Accident or Damages to the material i) To avoid such type of dangerous unsafe acts, use of mobile phones should Contractor & Customer
handling equipment) whilelifting due to lack of focus on the be avoided strictly. Also un-necessary communication with operators must be
job (e.g. talkingover mobile while avoided.
operating crane / hydra / forklift/ winch ii) The material handling equipment's like crane, hydra, forklift must be Contractor & Customer
etc.) / or not using of categorized skilled operated by AUTHORIZED LICENSE HOLDER DRIVERS ONLY.
manpower
iii) Alcoholic consumption strictly prohibited during working hours. at site Contractor & Customer
operating crane and other material handling equipment / vehicles.
a) Unsafe practice of cable laying from a) All electrical cables are to be laid down safely either underground or Contractor & Customer
Electrical connection electrical panel to site distribution board. overhead and through pipe conduit.
4 for erection / ground b) Safety sign to be displayed for caution, at all such location.
assembly work a) Main distribution board ELCB, of sufficient capacity / rating, should Contractor & Customer
b) Unsafe practices of cable connections
be provided with TPN facility, near ESP erection site.
/ joints (hand lamps / tools / earthing)
b) Cable extension boards should be used. Contractor & Customer
c) Proper earthing should be provided for all electrical appliances being used Contractor & Customer
at site. Earthing points to be checked and ensured.
d) All welding machines / other electrical tools are to be tested at site (for Contractor & Customer /
megger & current) for correct current rating. Thermax
e) Proper safe cover to be provided to all electrical appliances / boards Contractor & Customer
specially in rainy season
f) provide sufficient fire extinguisher / sand buckets near main DB & welding
machines.
a) Uneven ground floor resulting slipping Level the ground by back filling the soil at least 8-10 days prior to ground
of material during assembly assembly work, to avoid delay in activity. Contractor & Customer
5 Ground assembly
work b) Welding sparks / fire /electrical shock a) Do not keep the flammable items (e.g. acetylene or LPG cylinders) near Contractor & Customer
causing fire hazards and damages to welding / cutting area.
material & leading to accidents b) Ensure the availability of fire extinguisher (CO2 or water / sand) or sufficient Contractor & Customer
water while doing the hot work nearby flammable material.
c) Ensure that the surfaces being welded are in dry condition. Also ensure that Contractor & Customer
the welder is not over sweated which can cause accident due to electrical shock
181
Sl.
No.
182
c) Accidents due to gas cutting / back a) Use of correct size cutting sets / cutting nozzles / back fire arrestor to be done. Contractor & Customer
fire / leakage of gas The gas cylinders are to be kept in vertical position, preferably in cylinder trolley.
Use of tested gas regulators with pressure gauges. Use the cylinders with guard.
5 Ground assembly Use proper hose pipe with standard colour coding and proper hose clamps to be
work used to connect the hoses.
b) Ensure the availability of fire extinguisher or sufficient water while doing the Contractor & Customer
hot work.
d) Accidents due to grinding sparks / eye Use of PPEs like hand gloves, safety goggles, electrical appliances with proper Contractor & Customer
injuries / fire / electrical shock earthing should be used.
e) Accidents causing to hand / finger Use of PPEs like hand gloves, safety goggles, proper tools like wooden Contractor & Customer
injuries during hammering / fitting sleepers, packings while doing the work.
f) Accidents due to in-sufficient temporary
supports to component causing fatal Use of sufficient support to avoid falling of component being assembled.
accident / damages to material
Ground assembly a) Fall of derrick / fall of lifting Adequate safety precautions like are to be taken - i) Guy ropes, ii) Verticality of Contractor, Customer,
6
work arrangement &lifting support derrick after loading, iii) Barricade the area while erecting derrick, iv) Experienced Thermax Engineer
arrangement & skilled riggers need to be engaged for derrick erection
a) Use of PPEs Contractor & Customer
b) Hand and foot injuries b) Follow safe material handling procedure Contractor & Customer
c) Use of proper material handling tools & c) tackles Contractor & Customer
d) Periodic safety training Contractor & Customer
Contractor & Customer
c) Accidents resulting in loss of man-days a) Provide adequate space for ground assembly of components.
and affecting equipment performance b) All ground assemblies to be done on proper leveled platform Contractor, Customer,
due toinadequate facility / arrangement Thermax Engineer
for material being lifted c) Use of proper lifting tools / tackles (with test certificates) Contractor & Customer
d) Adherence to the sequence of erection, alignment & welding Contractor, Customer,
Thermax Engineer
e) Ensuring sufficient lifting lugs for material being lifted Contractor & Customer
f) Ensure the dry run of the material handling equipment, before lifting the
material.
d) Fatal accident due to not using proper a) Under any circumstances, use of lifting frame & assembly jig must be ensured, Contractor, Customer,
lifting frame / tools / locking arrangements as per Thermax drawing. Thermax Engineer (Not
for material being lifted. following the safety
precaution, will affect the
ESP completion schedule
and performance of ESP.)
Sl.
No.
e) Accidents due to lack of knowledge of a) The work group / supervisor should be briefed on the equipment knowledge Contractor, Customer,
equipment & poor communication / / activity knowledge. Thermax Engineer
inadequate work procedure & wrong b) For effective communication, arrange meeting for allocating responsibilities, Contractor, Customer,
6 Ground assembly erection sequence before commencing the work. Thermax Engineer
work c) Follow the sequence of mechanical installation.
d) Always responsible, authorised person must be available outside ESP, while Contractor, Customer,
workmen are working inside ESP. Thermax Engineer
a) Fatal accident / permanent disability a) Use of PPEs i.e. safety belt, helmet, safety shoes, hand gloves, safety goggles Contractor & Customer
etc.
b) Provision of proper scaffolding and ladder arrangement for working people Contractor & Customer
at higher elevation.
7 Working at height b) Inadequate facility to reach at high a) Provide proper ladders to have approach to ESP columns / girders after Contractor & Customer
elevation, resulting into fatal accident erection. Use of fall arrestor for the working men at height.
b) Provide the lugs / supports on upper end of material being erected, so that Contractor & Customer
workmen can hook the safety harness while doing the work at high elevation.
c) Falling of tools / scrap - debris / a) No man movements, on ground / lower elevation, is allowed while any work Contractor & Customer
erection material (cutting / erection / material lifting / fitting) is going on at higher elevation.
b) All tools, being used at high elevation should be tied to job, with proper Contractor & Customer
chain, to not to allow to fall.
c) Provide the safety barricade tapes below working area to avoid the entry of
personal.
a) Physical fitness certificate to be obtained by authorised physician Contractor & Customer
d) Physical fitness / Poor vision workmen
b) Continuous restless work, which can affect workmen fitness, should not be Contractor & Customer
while working at height
allowed.
e) High wind flow causing disturbance in a) No work should commence, if heavy windflow affects in safe work conditions Contractor & Customer
work activity which results in accident
a) Ensure that the fuses from incomer panels and put the board of 'MEN AT Contractor & Customer
WORK. DO NOT SWITCH ON'.
8 Electrical Installation a) Improper lock out while working with b) For cable termination, the sequence shall be followed from main equipment Contractor & Customer
electrical live power supply during to supply point e.g. MCC / ACP to TRCC or TRCC to TR set. First TR set cable
installation / sequence of cable termination termination to be done followed by termination at TRCC and then at MCC / ACP.
b) Improper way of cable pulling a) While pulling the cables vertically upwards, sufficient workmen to be Contractor & Customer
deployed at various elevation with use of PPEs.
b) Proper /suitable arrangement to be ensured for pulling / dropping the cable. Contractor & Customer
a) Cable extension boards should be used. Contractor & Customer
c) Unsafe practices of cable joints
b) Proper earthing should be provided for all electrical appliances being used Contractor & Customer
(hand lamps / tools / earthing)
at site.
183
Sl. Activities Hazards Safety Precaution Responsibility
No.
184
a) No hot work to be done near electrical / instrument items, without putting Contractor & Customer
8 Electrical Installation d) Hot work (gas cutting / welding / heating etc.) proper cover on the items.
near electrical / instrumentation items like cables, b) Follow the installation sequences Contractor, Customer,
TR sets, Heaters, Level sensors etc. Thermax Engineer
c) Equipment awareness to be given to the workmen Contractor, Customer,
Thermax Engineer
Accidents due to improper crimping / workman Use of proper tools / tackles for cable termination / crimping. All cable are to
be terminated with use of lugs. All activities are to be done by categorized
ship / inadequate measuring instruments
skilled personal. Proper and calibrated measuring instruments are to be
provided while doing the work.
e) Injury to fingers / hands while removing cable a) Use of PPE must be ensured Contractor & Customer
insulation / armour with knife b) Use of non-standard tools like knife / cutter must be stopped. Contractor & Customer
f) Operation of panel switch with naked hands i.e. a) Replace the damaged panel handles Contractor & Customer
switching ON panels without using panel handles b) Use the suitable insulated tools like, if required in urgency Contractor & Customer
9 Pre-Commissioning / a) Serious accident due to inhalation of dust a) Proper work permit must be obtained ensuring power lock out / men on Contractor, Customer,
Commissioning inside ESP (Confined Space) during ESP GD test work at panels, before entering ESP inside. Thermax Engineer
Activities b) Use of PPEs must be ensured before entering inside ESP for GD test. Contractor, Customer,
Thermax Engineer
c) Before entering inside ESP, ensure that there is no dust passing through ESP. Contractor, Customer,
This can be done by running the ID fan till stack is clean visually, before Thermax Engineer
entering inside ESP.
d) Proper communication tools must be used while conducting GD test. Contractor, Customer,
Thermax Engineer
e) Always responsible, authorised person must be available near, outside ESP, Contractor, Customer,
while conducting the GD test. Thermax Engineer
b) Hazards associated with electrical, Proper work permit must be obtained ensuring power lock out / men on work Contractor, Customer,
instrumentation, mechanical works i.e. entry in at panels, before entering ESP inside. Thermax Engineer
confined space (narrow area inside ESP),
non availability of interlocking system & improper
communication for the work activity
c) Serious accident due to poor illumination Sufficient illumination of 24V / 100W lamps are to be provided. Minimum two Contractor & Customer
inside ESP (confined space) lamps must be provided per group, out of this 1 must be used as stand by
Sl. Activities Hazards Safety Precaution Responsibility
No.
9 Pre-Commissioning / d) Chances of explosions inside ESP i.e. due to a) Install CO analyzer. ESP TR sets tripping interlocking to be incorporated if Contractor & Customer
Commissioning CO level is more than 2%
CO accumulation inside ESP / carry over of
Activities
uncontrolled, unburned inside ESP / improper b) In case if ESP ID fan is tripped for any reason, ESP purge air blower should Contractor & Customer
sequence of plant start up or shut down - All be switched OFF immediately.
resulting into ESP internal damages / ESP
b) Arrest all false air leakages inside ESP which supply oxygen to the fire. The Contractor & Customer
damage / Fatal Accident / Heavy losses to
sources of false air leakages might be from Rotary Airlock Valves, Inspection
property Doors, Hopper By-pass chute
Inhalation & Exposure of dust, mist, fumes, a) Wear suitable PPEs Individual
10 Working in
gaseous
hazardous zone b) Before entering around / inside equipment, measure hazardous gases (CO) Individual (Customer to
level and carry the instrument till person comes out of hazardous zone. give CO analyzer)
High noise levels Use of ear muff / ear plugs Individual
Exposure to high temperature Use the suitable PPEs. Individual

185
Chapter 16
Stack Sampling
Procedure
Stack Sampling Procedure

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
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.
Inlet Dust
Temperature in Gas Flow in Outlet Emission
Concentration
Sl. No ºC (At ESP inlet) AM³/hr in mg/NM³
in gm/NM³
Design Actual Design Actual Design Actual Design Actual
1.
2.
3.
Avg.
187
Sampling Port Arrangement Sketch No. 107
188
Sampling Port Arrangement Sketch No. 108
189
ENVIRO DIVISION
Chapter 17
List of Two Years
Operating Spares
List of Two Years Operating Spares
TWO YEARS OPERATING SPARES FOR ESP ( 90 / 120 KV Rating )
SR NO. DESCRIPTION QUANTITY
1 Support Insulator 2 Nos.
2 Shaft Insulator 2 Nos.
3 Support insulator heater 2 Nos.
4 Rapper Coil with shield 2 Nos.
5 Gasket for support insulators(1 set consists of 12 gaskets) 2 Sets.
6 Hypalon Boot 12 Nos.
7 Clamp for Hypalon Boot Big End 12 Nos.
8 Clamp for Hypalon Boot Small End 12 Nos.
9 PLC CARD for Micro Tapper Panel 1 Nos.
10 HMI for Micro Tapper Panel 1 Nos.
11 SMPS 2A for Micro Tapper Panel 1 Nos.
12 Row Board for Micro Tapper Panel 1 Nos.
13 Column Board for Micro Tapper Panel 1 Nos.
14 DC Thyrister Unit for Micro Tapper Panel 1 Nos.
15 Hopper level switch 1 Nos.
16 Purge air filter 1 Nos.
17 Diode for rapper 12 Nos.
18 Firing Module for TR set control Panel 1 Nos.
19 Controller for TR Set 1 Nos.
20 Thermostat for hopper heater 1 Nos.
For quick response please mention our equipment OC No. in the purchase enquiry.
For example E 7404 or E - 7423
190
ENVIRO DIVISION
Whome to contact
In case of problem
In case of problem, please contact :
CHENNAI REGION
THERMAX LIMITED, 312, ANNA SALAI, TEYNAMPET, CHENNAI-600018.
TEL:044-24353831(4LINES) FAX:044-24353841
DELHI REGION
THERMAX LIMITED, 9, COMMUNITY CENTER, BASANT LOK, NEAR PRIYA CINEMA, NEW DELHI 110057.
SERVICE MANAGER TEL:011-26145319 FAX:011-26145311
REGIONAL OFFICE KOLKATA REGION
THERMAX LIMITED, AZIMGANG HOUSE, 5TH FLOOR, 7, CAMAC STREET, KOLKATA.
TEL:033-22826711/12/13 FAX:033-22826796
MUMBAI REGION
THERMAX LIMITED, DHANRAJ MAHAL, CHATRAPATI SHIVAJI MARG, COLABA, MUMBAI- 400039.
TEL : 022-22045391 FAX:022-22040859
CHENNAI REGION
THERMAX LIMITED, 312, ANNA SALAI, TEYNAMPET, CHENNAI - 600018.
TEL:044-24353831(4LINES) FAX:044-24353841 Email:ssrinivasan@thermaxindia.com
DELHI REGION
THERMAX LIMITED, 9, COMMUNITY CENTRE, BASANT LOK, NEAR PRIYA CINEMA, NEW DELHI 110057.
CORPORATE REGIONAL TEL:011-26145319 FAX:011-26145311 Email:glal@thermaxindia.com
MANAGER KOLKATA REGION
TH
THERMAX LIMITED, AZIMGANG HOUSE, 5 FLOOR, 7, CAMAC STREET, KOLKATA.
TEL:033-22826711/12/13 FAX:033-22826796 Email:amukherj@thermaxindia.com
MUMBAI REGION
THERMAX LIMITED, DHANRAJ MAHAL, CHATRAPATI SHIVAJI MARG, COLABA, MUMBAI 400039.
TEL:022-22045391 FAX:022-22040859 Email:fbacha@thermaxindia.com
THERMAX LIMITED, GREEN HOUSE, 148, MUMBAI-PUNE ROAD, PIMPRI, PUNE - 411 018.
SERVICE MANAGER TEL:020-27426013
HEAD OFFICE Email: jagdish.dulange@thermaxindia.com, prakash.mahale@thermaxindia.com
adutta@thermaxindia.com
THERMAX LIMITED, ENVIRO DIVISION, PMT COMPLEX, BEHIND PCMC BUILDING., MUMBAI-PUNE ROAD,
DIVISIONAL HEAD PUNE 411 018.
TEL:020-66122999 FAX:020-27426532 / 33
191
X
THERMAX LIMITED
ENVIRO DIVISION
PMT Complex, Behind PCMC Building, Mumbai - Pune Road, Pimpri,
Pune - 411018, Maharashtra, India.
Phone : 020 27475941, Fax : 020 27426532, Web: www.thermaxindia.com
In view of our constant to improve the quality of our products, we reserve the right to alter or change specifications without prior notice.
Doc. No. T-ENV-DE-M-007 RO. DT. 01.06.2007

Erection Manual - TL Design Esp

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ELECTROSTATIC PRECIPITATOR

Improving Your Business

Sr. No. Chapter Page No.

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

15. SAFETY RISK ASSESSMENT FOR ESP ACTIVITIES 179

16. STACK SAMPLING PROCEDURE 186

17. LIST OF TWO YEARS OPERATING SPARES 190

1. Assist in understanding the construction features of THERMAX make ESP.

For any doubts or clarification, feel free to contact us at following address

M/s THERMAX LIMITED

Installation & Commissioning Department

Guidelines on Health & Safety Measures

Following minimum health & safety measures are recommended.

Principle of ESP Operation

Facilities for THERMAX Site Supervisor

Guidelines on Storage Facilities & Storage Instructions

The storage area should be located near to the unit to be installed.

Guidelines on Receiving & Stacking of Material

Sketch No. 001 - Handling Instructions

Standard ESP Activity Chart with Main & Parallel Activities

17. Fixing of mechanical interlock system, Sign and brackets

1 ESP Identification Visual 100% As per Drawing P W W

2. Supporting Identification Visual 100% As per Drawing P W W

3. Structural Identification Visual 100% As per Drawing P W W

Casing, Inlet & Identification Visual 100% As per drawing P W W

Alignment Visual 100% As per Drawing P W W

12. Purge Air Identification Visual 100% As per Drawing P W W

16. Transformer Identification Visual As per Drg. P W W

Functional operation Wiring check 100% PCR P P W

17 Mechanical Key Identification Visual 100% As per Drg. P W W

18 Rapper Control IR Test By Megger 100% As per Pre- PCR P P W

Panel Functional check 100% commissioning Report PCR P P W

19. Hopper heaters Identification Visual 100% As per Drawing P W R

Guidelines on ESP Pre-Erection Activities

Sl. Description Allowable Deviation

Procedure for making template

Sketch No. 002 Footing Center Line Marking

Sketch No. 003

Sketch No. 004 Footing Center Line Marking

Sketch No. 005 Foundation Alignment Protocol

B. Verification of the ESP Material Received:

C. Ground Assembly of ESP Parts:

Following is the brief procedure about the assembly of above parts.

D. Inlet Nozzle with Gas Distribution Screen

E. Outlet Nozzle with Gas Distribution Screen

F. Casing columns with Casing panels

Sketch No. 006 Nozzle Assy Panel Fit-Up

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

Sketch No. 008 Casing And Hopper Fit-Up Details

Sketch No. 14 Casing And Hopper Fit-Up Details

Sketch No. 20 Casing And Hopper Fit-Up Details