Format No. : CP 01 F03 Rev. No.

: 01 Page : 01 of 09

PROJECT: FGUTPP UNCHAHAR STAGE III (1 X 210 MW)

PROCEDURE FOR AIR-IN-LEAK TEST OF ESP

DOCUMENT NO: PN:T !:"#$:00:"00# PREPARED '( * '. +. RO(, I UED TO

EFFECTIVE DATE 1%&0%&"00# REVIE)ED '( * . +. A-A, APPROVED '( *'. . '. RAO,

COP( NO : DATE OF I UE

UED '(: -EAD&T !

BHARAT HEAVY ELECTRICALS LIMITED

TECHNICAL SERVICES PSNR NOIDA

DOC.NO.: PN:T !:"#$:00:"00#

PA.E 0" OF 09

CONTENTS

1.0 2.0 .0 ".0 #.0

DESIGN PARAMETERS OF ESP SCOPE PRE-RE!UISITES TEST PROCEDURE TEST SET UP

This procedure is the property of BHEL and is exclusively developed for the commissioning of UNCHAHAR TA!E" ### $%&$' () UN#T* This procedure should not +e used +y any other person or firm ,ithout the ,ritten permission of BHEL -.o,er ector Northern Region/ Technical ervices0 or put to any use other than specified a+ove* This document shall not +e copied in any manner unless authori1ed*

DOC.NO.: PN:T !:"#$:00:"00# 1.0 DESIGN PARAMETERS OF ESP 2.0 Flue gas flow rate FOR ALL 4 PASSES Flue gas temperature at inlet in ESP #nlet $ust %on$ition w&en firing 'esign %oal +uarantee$ Air,in,lea-age in,to ESP : : : : :

PA.E 03 OF 09

341.3 m3/s 12 !" (.) g/*m3 1 . of +uarantee point flow 3.41 m3/s

SCOPE An air tig&tness test s&all /e performe$ on ea%& of t&e pre%ipitator on %ompletion of ere%tion of ESP %asing &opper inlet / outlet funnels wit& all t&e internals fille$ in as per appro0e$ $rawing. 1&e test s&all /e %on$u%te$ for $ifferent pressure %on$itions 0i2. 133 mm 1 3 mm 233 mm 2 3 mm an$ 333 mm water %olumn.

3.0

PRE-REQUISITES Owner4s fl5 as& remo0al s5stem s&all not /e %onne%te$ to t&e &opper. #nlet an$ outlet $u%t %onne%tions s&all /e left open. 41 67 3 p&ase7 3 82 temporar5 ele%tri%al suppl5 for %on$u%t of t&e test s&all /e pro0i$e$.

4.0

TEST PROCEDURE 9lan- off inlet an$ outlet funnel openings /5 suita/le plates. 9lan- off &opper outlet openings /5 suita/le plate. "lose all man&oles on t&e roof7 inspe%tion $oors on t&e %asings an$ t&e &oppers.

5.0

TEST SETUP :ount t&e Fan an$ motor arrangement in line wit& t&e 6enturi,meter an$ %onne%t it to t&e flange of an5 one of &oppers. So t&at pressuri2ation of ESP internals %an /e $one t&roug& t&is arrangement. :ount a ;<4 tu/e manometer on a tapping pro0i$e$ on t&e &opper a$=a%ent to t&e pressuri2ation e>uipment as s&own in Fig. *o. 1.

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On%e all -nown openings are %lose. Pressurise t&e ESP /5 fan an$ motor arrangement su%& t&at t&e %onstant pressure $ifferential is maintaine$ in ;<4 tu/e manometer mounte$ on t&e &opper ?least %ount 1mm@. O/ser0e t&e 0olume of air /eing pumpe$ in7 for %onstant pressure $ifferen%e /5 t&e pressure $rop a%ross t&e 6enturi,meter.

Repeat t&e test for num/er of rea$ings of $ifferent pressure an$ note $own t&e %orrespon$ing pressure $ifferentials a%ross t&e 6enturi,meter. 5.1 THEORY A&en sta/le %on$itions are esta/lis&e$7 t&e mass flow rate of air t&roug& t&e fan7 6enturi,meter an$ t&e pre%ipitator must /e %onstant. 1&e flow rate of air for t&e fan is mf B C

A&ere C B 6olumetri% flow of air in m3/&our B t&e $ensit5 of air at test %on$itions in -g/m3

1&e mass flow rate t&roug& t&e 0enture %an /e written as fun%tion of t&e pressure $ifferential an$ %o,effi%ient of $is%&arge for t&e 6enturi. B D - 0ent D w&ere - 0ent t p 0ent B "o,effi%ient of $is%&arge for 6enturi,meter B 1&e $ensit5 of air B 1&e pressure $ifferential a%ross 6enturi in mmA%.
p 0ent

1&e mass lea-age of air t&roug& Ele%trostati% Pre%ipitator %an /e eDpresse$ as

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: filter A&ere7

B 2 D

Psfilter

E filter Ps filter 2 1 D - 0ent D

t

B A %onstant to /e $etermine$. B Stati% pressure of air insi$e Ele%trostati% Pre%ipitator ?Pressure $ifferential as o/ser0e$ in ;<4 tu/e manometer@. B 1&e $ensit5 of air at Ele%trostati% Pre%ipitator %on$ition.
p 0ent

B 2 D - filter D

Ps filter

for pra%ti%al purpose 1 %an /e ta-en as 2 1&erefore7 E filter B E 0ent D

p 0ent Psfilter

. . . . . . . . . ?1@

An$ t&e lea-age %an /e eDpresse$ as C lea-age A&ere filter B 1&e $ensit5 of gas at t&e operating %on$itions. Ps filter B 1&e a%tual stati% o0er pressure in Ele%trostati% Pre%ipitator. 1&e tests are %on$u%te$ for $ifferent Ps filter ?mmA%@ %on$itions 0i2. 1337 1 37 2337 2 37 333 mm of A" /5 suita/l5 0ar5ing t&e $amper %ontrol of t&e fan. "al%ulate E filter from t&e -nown 0alues of e>uation ?1@. #t ma5 /e inferre$ t&at E filter is a %onstant. 5.2 SAMPLE CALCULATION C Lea-age B E filter D
Ps filter

B E filter D

Ps filter

. . . . . . . . . . . . . ?2@

DOC.NO.: PN:T !:"#$:00:"00# E filter A&ere7 Ps filter B A%tual stati% pressure in ESP B E 0ent D
p 0ent Psfilter

PA.E 00 OF 09

filter B 'ensit5 of gas at operating %on$ition ?3.(F4 -g/m3@ E 0ent B 6enturi meter %onstant ?3.143@ GP B Pressure $ifferen%e measure$ a%ross 0enturi meter Ps filter B ESP stati% pressure measure$ in < H tu/e manometer EG: *o of ESP s per /oiler B 2. 1&e $esign gas flow of t&e ESP is 121 m3/s an$ 1&e air in lea-age allowe$ is 1 . i.e. 1.21 m3/s. Lea-age per ESP B 3.I3 m/se% A E0ent of 3.143 is %onsi$ere$ for t&e 0enturimeter use$. 1&e rea$ings ta-en in /ot& t&e passes are ta/ulate$ /elow. PASS - A Ps f !"#$ % &&'C 333 2 3 233 1 3 133 PASS - / Ps f !"#$ % &&'0 133 1 3 233 2 3 333 (P )#%" % &&'0 3. . (.3 ).3 11. E filter ?A0erage@ * f !"#$ + * ,#%" -(P.Ps f !"#$ 3.32F 3.32F 3.32) 3.32F 3.32( 3.32FI (P )#%" % &&'C 2 21 1F 12. (. E filter ?A0erage@ * f !"#$ + * ,#%" -(P.Ps f ! 3.341 3.341 3.342 3.341 3.342 3.3414

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1 2ea3age for Pa44 A 5 0./1/ 6 7 1%0 & 0.%$/ 5 0.#9/ m3&4 1 2ea3age for Pa44 A 5 0."$0 6 7 1%0 & 0.%$/ 5 0.390 m3&4 Tota2 2ea3age 89 E P 5 1 2ea3 Pa44 A : 1 2ea3 Pa44 ' 5 0.#9/ : 0.390 5 0.990 m3&4

PA.E 0$ OF 09

T;<4 t;e a8r 89 2ea3age 84 2e44 t;a9 t;e g<ara9tee= va2<e of 1."1 m3&4.