Index

1. Introduction to Manual ..........................................................................................................003

2. Guidelines On Health and Safety Measures:........................................................................004
3. Principle of ESP Operation ...................................................................................................007
4. Facilities for THERMAX Site Supervisor...............................................................................008
5. Guidelines on Storage Facilities & Storage Instructions.......................................................009
6. Guidelines on Receiving & Stacking of Material ...................................................................011
7. Standard ESP Activity Chart With Main & Parallel Activities ................................................015
8. Guidelines on ESP Pre-Erection Activities ...........................................................................021
9. Guidelines on ESP Mechanical Erection Activities ...............................................................039
10. Electrical Activities ................................................................................................................143
11. ESP Pre–Commissioning Checklists ....................................................................................157
12. Pre – Commissioning Activities ............................................................................................162
13. Commissioning Activities ......................................................................................................174
14. Precautions for smooth & trouble free functioning of ESP....................................................180
15. Safety Risk Assessment for ESP Activities ..........................................................................185
16. Stack Sampling Procedure ...................................................................................................192
 THERMAX LTD., ENVIRO DIVISION, PUNE

1. Introduction to Manual

This guideline manual covers the main features of ESP installation and commissioning of
THERMAX make Electrostatic Precipitators. The instructions given in this guideline manual
are not intended to explain all the 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

Installation & Commissioning Department

 THERMAX LTD., ENVIRO DIVISION, PUNE

2. Guidelines On Health and Safety Measures:

During erection activity of the ESP, Customer / Erectors must take care of all health and
safety measures, as per the rules and regulations applicable in the local area where ESP
installation and commissioning is to be done. For any failure/s, due to negligence of safety
and health issues, Thermax will not be responsible.

Following minimum health & safety measures are recommended.

1. First aid boxes must be kept at easily accessible places of the work site.
2. At least two trained persons in the first aid treatment must be present while the work
is in progress at erection and / or fabrication / assembly site.
3. Site contractor’s all workmen must be introduced to safety and health program,
before commencing the erection / fabrication / assembly activity.
4. Emergency telephone numbers like plant medical aid, fire station, plant security
gate, nearest hospital must be kept handy by contractor’s all supervisors. Also these
telephone numbers are to be displayed prominently in front of customer’s,
Thermax’s and contractor’s site offices for ready reference to all workmen.
5. All plane equipment / machines like cranes, winch, lifting equipment, welding
machines, gas cutting sets etc, must be operated by only trained and authorised
operators.
6. All personnel working at site must wear the basic PPEs like safety helmets, safety
shoes. The other safety items like safety belts, safety goggles, earplugs, welding
screens, masks and gloves etc, should be used as and when required.
7. Barricades and danger warning signs must be displayed at all locations to prohibit
the entry of unauthorized persons.
8. A considerable portion of the ESP alignment work is done in confined space. Hence
precautions related to working in confined space must be adhered.
9. The ESP erection takes place at high elevations. Hence special care must be taken
while working at high attitude. Lifeline, platform / handrails, barricades, temporary
platforms / ladders must be made available whenever required.
10. For welding the temporary ladder / steps on casing columns, use only plain mild
steel rods. The tor steel rods must not be used for this purpose, as welding of tor
steel with mild steel is not safe.
11. While working at height, the workmen need to tie the safety belt (full body harness)
at one fixed location. For this purpose, always weld a proper lug on the top area of
the item being lifted, at needed places, so that workmen can tie his safety belt to
such lugs when ever he goes on top.
12. All the lifting equipment e.g. crane, winch, other material handling equipment like
chain blocks, hydra, fork lift, silings, wire ropes, D-shackles, rope pulleys etc. must
be tested for their safe work loads. Such test certificates from an authorised agency
must be submitted while bringing the equipment at site. All safety alarm and controls
of material handling equipment should be available in working condition.
13. Whenever the erection work at height is going on, no man movements are allowed
below such area. Safe working barricades should be provided in such area.
14. While shifting the material from store yard / assembly point to erection site the
necessary safety precautions to be taken to avoid the fall of material, that could
result in serious accident.
 THERMAX LTD., ENVIRO DIVISION, PUNE

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 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.
 THERMAX LTD., ENVIRO DIVISION, PUNE

3. 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 cross-
section 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 electrodes.
Discharge electrodes (Regitrodes) are suspended in a plane midway, between each pair of
collecting electrodes.
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 electrodes. 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 an 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.
 THERMAX LTD., ENVIRO DIVISION, PUNE

4. 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.
 THERMAX LTD., ENVIRO DIVISION, PUNE

5. 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
funnel 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/ 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 be 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 the lift markers.
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 where 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.
THERMAX LTD., ENVIRO DIVISION, PUNE

b. The crates of electrodes, as eventually also the single plates, have to be stored
with their wide side upright to avoid sagging of the electrode plate.
c. While unloading with crane, provide a lifting device. Lift the crates always with four
slings of rope (protect the four points of attach) and leave them in their original
position without turning.

11. 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 corrosion.

ATTENTION: Non observance of the above instructions will absolve

THERMAX from every liability concerning erection problems.
 THERMAX LTD., ENVIRO DIVISION, PUNE

6. 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
acknowledgement from the transport 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 while
unloading.
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.
THERMAX LTD., ENVIRO DIVISION, PUNE

b. ESP Casing, Hopper: The ESP casing 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. 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
given below (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.
THERMAX LTD., ENVIRO DIVISION, PUNE

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 on 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.
 THERMAX LTD., ENVIRO DIVISION, PUNE

7. 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 if
Casing Panels with and Alignment Inlet Nozzle with GD
columns Screen
3.1 Ground Assembly of Outlet 3. ESP Bearing installation and 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 Erection, Alignment and
Welding of Inlet Nozzle panels ( by crane / by Welding of Outlet Nozzle
with GD Screen winch) with GD Screen
8. Alignment of collecting
panels
9. Positioning of top HV frame Erection, Alignment and
( by crane / by winch) Welding of ESP penthouse
10.1 Erection, Fit-up and 10. Fixing of rigitrodes to top HV 2 Erection of Monorail with
welding of inner roof frame its structure
11.1 Erection of hopper and its 11. Installation and Alignment of 2 Erection of TR set base
allied parts. Fix regitrode support insulator and its frame and TR set
guide frame temporary allied parts
support inside the hopper.
12.1 Fixing of electrical items 12. Loading of support
insulators
13.1 Fixing of the cable trays 13. Checking the straightness of 2 Erection & Alignment of
on ESP, for all cables (like regitrodes in free hanging collecting plate Rapping
power cables, control condition and its System
cables, Feedback Cables straightening if required
etc.)
14.1 Cable laying 14. Fixing the guide frame to 2 Erection & Alignment of
regitrodes Regitrode Rapping System
15.1 Cable Termination 15. Alignment of regitrodes 2 Erection & Alignment of
w.r.t. collecting plates Inlet GD Rapping System
16.1 Cable Dressing 16. Air leak test 16.2 Thermal Insulation
Application (After Air Leak
Test)
17. Fixing of mechanical interlock system Sign and brackets
 THERMAX LTD., ENVIRO DIVISION, PUNE

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–

Activity No. Approx. day of TL

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
Pre–Erection 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.
 THERMAX LIMITED, ENVIRO DIVISION, PIMPRI, PUNE 411 018 THERMAX
FIELD QUALITY PLAN FOR ESP
Document No.: TL/ENV/FQP-ESP/38 Rev. 0 dtd. 15.03.06
Sr. Description Characteristics to be Method of Extent of Acceptance Erection Thermax Customer
No checked check check standard Agency
1. Supporting Identification Visual 100% As per Drawing P W W
Structure, Elevation Measurement 100% As per Drawing P W W
Platforms and Orientation Visual 100% As per Drag+/-5mm P W W
other Structural Dimension Measurement 100% Verticality1mm/mtr P W
members Straightness (level) / Measurement 100% As per Drawing P W
Verticality Measurement 100% Protocol No.T-EPD- P W
Fit up SR-F-019 – Available
Primer Touch Visual 100% in the erection P W
Visual 100% manual P W
2. Structural Identification Visual 100% As per Drawing P W W
Bearing Orientation Visual 100% As per Drawing P W W
Condition Visual 100% P W W
Alignment Measurement 100% As per erection P W W
drawing
Sprit & Water Level of Visual 100% P W W
bearing top
3. Casing, Inlet & Identification Visual 100% As per condition P W W
Outlet Nozzle, Condition Visual 100% P W W
Hopper, Roof Healthiness Visual 100% P W
Panel, Fit up (diagonals & Measurement 100% As per erection P W
Penthouse dimensions) drawing
Primer touch Visual 100% P W

4. Collecting Identification Visual 100% As per Drawing P R R

System and Condition Visual 100% P W R
Emitting Healthiness Visual 100% P W R
system Assy. Fit up Visual 100% P W R
Alignment Distance Random P W W
between
Collecting
 regitrode as per
Drawing
5. Collecting and Identification Visual 100% As per Drawing P W R
Rigitrode Condition Visual 100% As per Drawing P W R
Rappers Healthiness Visual 100% P W R
Fit up Visual 100% As per Erection P W R
Alignment / verticality Measurement 100% Drawing P W
6. Support & Identification Visual 100% As per Drawing P W R
Shaft Insulators Condition Visual 100% As per Drawing P W R
Healthiness Visual 100% P W R
Fit up Visual 100% P W
7. Gas Identification Visual 100% As per Drawing P W R
Distribution Condition Visual 100% As per Drawing P W R
Screen Healthiness Visual 100% P W R
Fit up Visual 100% As per Erection P W R
Alignment / verticality Measurement 100% Drawing P W
8. Expansion Identification Visual 100% As per Drawing P W R
Joints & Condition Dimensions Visual 100% As per Drawing P W R
Hopper Slide Healthiness Measurement 100% As per Drawing P W R
Gates Fit up Visual 100% As per Drawing P W R
Alignment Measurement 100% As per Erection P W
Drawing
9. Purge Air Identification Visual 100% As per Drawing P W R
system Condition Visual 100% As per Drawing P W R
Healthiness Visual 100% P W R
Fit up Visual 100% As per Erection P W
Alignment Measurement 100% Drawing P W
Functional check Visual 100% Direction of rotation & P W R
Current drawn
10. Welding Identification of As described 100% Kerosene test / P W W
Leakage Test of Welding Leakages below Smoke test
ESP after box-
up
11. Thermal Identification Visual 100% As per Drg. P W W
Insulation

12. Cable laying / Identification Visual 100% As per Drg. P W R

Termination
and Earthing
13. Transformer Identification Visual As per Drg. P W W
Rectifier Set Location Visual As per Drg. P W W
Electrical Tests Measurement As per TR Set P W R
manual
14. Mechanical Key Identification Visual 100% As per Drg. P W W
Interlock Location Visual 100% As per Drg. P W W
System Testing Operation 100% As per Drg. P W W

15. TR Panel & TR Die electric Strength BDV Tester 100% Should be more than P W R
set Testing of Transformer Oil 50KV with 2.5mm
Lamp Load test gap
Using 100w 100% NA P W W
Short Circuit Test lamps in series
100% To the rated value of P W W
Open Circuit Test the secondary
IR Test 100% current P W W
Functional operation To the rated value of
check By megger 100% secondary voltage P W W
Wiring check 100% P W W
and charging As per electrical P W W
panel wiring diagram
16. Rapper Control IR Test By Megger 100% >50 M ohms P W W
Panel Functional check Coil energisation 100% Intensity as per field P W W
through panel for requirement
controls
17. Hopper heaters Identification Visual 100% As per Drawing P W R
(if applicable), Condition Visual 100% As per Drawing P W R
Insulator Healthiness Visual 100% P W R
heaters & Fit up Visual 100% As per Erection P W
Hopper level Alignment Measurement 100% Drawing P W
switches. Functional check Visual 100% Operation / Current P W R
drawn
18. Air Load Test As per Thermax Energising TR 100% As per Thermax P W W
Standard Format panels & TR Format T-EPD-SR-F-
sets with ESP 023
fields.
Note:
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.
After ESP is boxed up, i.e. after fixing the access door, rapper seals, insulator heaters, thermostats, hopper level probes, blank the
ESP inlet and outlet by either closing the dampers (if they are available) or by fixing a blanking plate and 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.
Then start the Purge air blower and pressurise the ESP. 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.

Legend:
P – Perform W – Witness R – Review
 THERMAX LTD., ENVIRO DIVISION, PUNE

8. 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 measurement 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 Z–axis.
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 –
THERMAX LTD., ENVIRO DIVISION, PUNE

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.
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 & Y–axis)] 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).
THERMAX LTD., ENVIRO DIVISION, PUNE

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 assembly of inlet nozzle.
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 lie 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.
THERMAX LTD., ENVIRO DIVISION, PUNE

Similar procedure of kerosene should be followed for site weld joints.

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) & 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, endure that the panel’s stiffener sides are kept one
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.
THERMAX LTD., ENVIRO DIVISION, PUNE

7. Weld the GD screen hanging arrangement on nozzle’s top plate, as shown in

referred drawing.
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 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
sent separately, 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.
THERMAX LTD., ENVIRO DIVISION, PUNE

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. 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 clearance available, a hopper can be assembled in one or two
pieces (height–wise). 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.
THERMAX LTD., ENVIRO DIVISION, PUNE

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.
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 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.
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.
THERMAX LTD., ENVIRO DIVISION, PUNE

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 given 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.
 THERMAX LTD., ENVIRO DIVISION, PUNE

9. Guidelines on ESP Mechanical Erection Activities

The list of activities involved in ESP erection and commissioning is briefed above 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.
 THERMAX LTD., ENVIRO DIVISION, PUNE

B. Support Structure Erection, Alignment and Welding

i) For erection, alignment & welding of support structure, refer support structure
drawing sent separately alongwith the attached schematic sketches (nos. from
031 to 032).
ii) After completion of foundation checking and foundation bolt grouting, the support
structure erection shall be started.
iii) Do the micro chipping of the foundation top surface, where the packing plates are
to be placed.
iv) 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.
v) 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.
vi) 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.
vii) 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 & 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 +/- 3mm w.r.t. fixed bearing column

viii) 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.
ix) Only after completing the support structure alignment, welding of support
structure bracing should be done.
x) While welding the bracings, the thought on the erection of collecting plate,
regitrode, hopper should be given.
THERMAX LTD., ENVIRO DIVISION, PUNE

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.
 THERMAX LTD., ENVIRO DIVISION, PUNE

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
c. For its correct spirit level
vi) The bearing alignment must be checked w.r.t. FIXED BEARING ONLY.
vii) Following guideline shall be considered for acceptable tolerances of bearing
alignment–

Sl. No. Description Allowable Deviation

1 Axial measurement in X & Y axis + / - 2 mm
2 Diagonal measurement 1 mm/m or 5 mm (whichever is
(Individual / Overall) min.)
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. A B A B A B A B
1 1 2 2 3 3 4 4
Inspection Spirit Level
Point
Water Level w.r.t.
Fixed Bearing

Mark √ if inspection point is as per above tolerance guidelines and mark X if it is

not as per tolerance guidelines.

Note: To ensure the correct elevation of bearing top and spirit level of bearing top
plate, the needed packings should be given only at base of support
structure column and not below any bearings.
THERMAX LTD., ENVIRO DIVISION, PUNE

viii) 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.
x) After completion of bearing alignment, further erection can be started.

HOLD POINT: FURTHER ERECTION OF ESP ON ESP BEARINGS SHOULD

NOT BE DONE, UNTILL COMPLETION AND ACCEPTANCE OF
BEARING ALIGNMENT.
 THERMAX LTD., ENVIRO DIVISION, PUNE

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 top and bottom
girders shall be done. This will form a box structure of erected assemblies and will
have better stability.
x) Repeat the above sequence for other assembled casing columns & panels /
respective top & bottom girders.
xi) Once all assembled casing column / panel, top / bottom girders are positioned,
the alignment of the columns can be done for its plumb (verticality) and axial /
diagonal measurements.
Following guidelines shall be followed for acceptable tolerances –

Sl. No. Description Allowable Deviation

1 Axial measurement in X + / - 5mm
& Y axis
2 Diagonal measurement 1mm/mtr or 8mm (whichever is min.)
(Individual / Overall)
3 Verticality / Plumb + / - 1mm/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 the casing alignment, the 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.
THERMAX LTD., ENVIRO DIVISION, PUNE

HOLD POINT: FURTHER ERECTION OF ESP COMPONENTS SHOULD NOT

BE DONE, UNTILL ACCEPTANCE OF CASING ALIGNMENT
AND WELDING OF GIRDER WITH COLUMNS.
 THERMAX LTD., ENVIRO DIVISION, PUNE

E. Erection, Alignment and welding of Staircase & Platforms with Access Doors

i) After completing the 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 109–A to 109–C for
fixing the doors.
 THERMAX LTD., ENVIRO DIVISION, PUNE

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.
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.
 THERMAX LTD., ENVIRO DIVISION, PUNE

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 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 to 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 both these 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 plate 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.
PLEASE NOTE UNDER ANY CIRCUMSTANCES THE 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.
THERMAX LTD., ENVIRO DIVISION, PUNE

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 between jig and ground, the clearance of approx. 800-900mm
should be maintained. This is required for movement of persons for welding of
collecting plate assembly.
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 all
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 of
M6X24long 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 other 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.
THERMAX LTD., ENVIRO DIVISION, PUNE

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.
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 plates are stacked over each other. Due to weight of upper
plate assemblies, there are always chances of getting damaged 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.
 THERMAX LTD., ENVIRO DIVISION, PUNE

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 –
A. By Winch (Manual or Electric) and
B. 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 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 completed before starting plate assembly erection.
v) Note that 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.

1. By Winch (Manual or Electric)

Following are the brief guidelines for erection of collecting plates by winch.

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 the 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 load, 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.
 h) Run the winch rope in such a way that the wire rope does not scratch to any part
of ESP incl. its foundation.
i) Place a channel box (fabricated from ISMC 200), on the top girder of the ESP 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 the 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 the lifting frame, the
frame should be lifted through 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
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
other plates)
p) After positioning the plate assembly inside the 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 the other 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 designed.
2. 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 installation, the
installation should be done from ESP top. Hence prior to starting the plate
assembly erection, availability of sufficient top clearance to be ensured, for
easy lifting of the collecting plates 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 at its
original position, after completing the installation work.
d. The lifting equipment (crane) 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 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 by running the system with lifting frame
only.
i. After successful dry run trials, as briefed above, the plate assemblies should
be shifted from the 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 of the collecting plate assemblies from assembly jig
to stacking area.
j. Insert the collecting plate assembly in the lifting frame and lock it properly, to
avoid its falling down / slipping during its lifting. The collecting plate assembly
should not be tied permanently with the lifting frame, as it would result in
problems while removing the frame after collecting plate assembly is fixed in
its position in the floating channel.
Note: COLLECTING PLATE INSTALLATION IS NOT ALLOWED
WITHOUT USING LIFTING FRAME.
k. Once collecting plate assembly is inserted and locked in the lifting frame, the
frame with plate can be lifted and can be taken to the position where it is
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 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 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 brought within control.
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 other
plates)
n. After positioning the plate assembly inside the 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 the erected plate assembly and then the lifting frame should be
taken outside ESP, from ESP top.
p. Then it should be placed on ground, so that next collecting plate assembly
can be inserted in the lifting frame and it can be erected in a similar way.
q. Similar procedure shall be adopted for installing the other collecting plates.
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 designed

I. Alignment of Collecting Panels

Once the collecting plate erection is completed, the 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 the 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 field, as shown in schematic sketch 052. Always check the
plumbness at the edge of the collecting plate.
b. Ensure that the 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 the 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 the 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.

ii) Spacing of the Collecting Plates.

a. After checking & ensuring the 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 is shown in sketch nos. 053 to
061.

Similar procedure shall be followed for alignment of collecting plate assemblies

in other fields.
 THERMAX LTD., ENVIRO DIVISION, PUNE

J. Positioning of top HV frame with other HV system components

a. After completing the collecting plate alignment, the 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 for this purpose.
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 the top HV frame is
done.
d. Ensure the correct water level of the temporary support brackets of top HV frame. 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, place the top HV
frame on it. This can be done by crane or winch. While lifting the top HV frame,
sufficient care should be taken to avoid the slipping of the HV frame resulting in
major accident & / or damages to the material.
f. While positioning the top HV frame on temporary support brackets, ensure that the
position of corner regitrode mounting hole location is at the center of respective gas
passage or collecting plates. This is described in the attached schematic sketch no.
075.

K. Erection, Fit-up and Welding of Inner Roof

a. Once the top HV frame is positioned, the 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 the 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 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, the penthouse erection can be started.
For this purpose refer the penthouse drawing sent separately along with the typical fit up
details shown in attached schematic sketches nos. from 064 to 066.
 THERMAX LTD., ENVIRO DIVISION, PUNE

M. Installation and Alignment of Support Insulator and its allied parts:

After completion of penthouse erection, further 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 the top HV frame positioning and penthouse erection is completed, the
regitrode rapper rod can be bolted to the top HV frame. While fixing the regitrode
rapper rod to HV frame, the 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 the verticality.
This can be done by intermittent welding of rapper rod to HV frame.
After welding, again the 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 the regitrode rapper rod is
at the center of the suspension plate. At least 2 rounds of gasket rope should be
provided between suspension base and roof plate. Also spirit level of the suspension
plate must be ensured.
c. Then install the slide base, with hyperbolic tube. Here also the 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 the
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 the support insulator.
e. Then install the insulator flange plate with gasket. After installing the flange plate,
once again check the spirit level of insulator flange plate.
While fixing the insulator flange plate, check the direction of the 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.
f. 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.
g. Tighten the rapper rod nut slowly, so that HV frame load can be transferred on
support insulators. To have correct loading, the tightening should be done
simultaneously for all rapper rod nuts of the field. The tightening should be in such a
way that the top HV frame is just freed from its temporary supports.
Once the top HV frame is free from temporary supports, re-check the alignment of
HV frame (water level and its position w.r.t. corner collecting plates – as it was done
while positioning the top HV frame on temporary frame & shown in sketch 075).
After getting the correct alignment, the regitrode fixing should be started.

HOLD POINT – UNLESS UNTILL ALL THE CHECK POINTS, MENTIONED

ABOVE ARE ENSURED, FURTHER ERECTION OF REGITRODE
SHOULD NOT BE DONE.
 THERMAX LTD., ENVIRO DIVISION, PUNE

N. Erection of rigitrodes to top HV frame and its straightness checking

After ensuring the top HV frame alignment, the 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 the availability of sufficient ground clearance.

b. If sufficient clearance is available, the regitrodes can be erected one by one
with the help of manila rope with a J-type hook at its lower end.
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 10–12mm diameter. The open end of J hook 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 spike straightness of all electrodes.
DO NOT ERECT THE REGITRODES WITH BEND PINS.
After lifting the regitrode, it has to be taken to the 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, the straightness of regitrodes
must be ensured before regitrodes are fixed to the 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 the 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 erection of first regitrode, repeat the similar procedure
for erection of other regitrodes.
g. Once the 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 the bow of regitrode accurately the gauge similar to “T”
gauge can be used.
THERMAX LTD., ENVIRO DIVISION, PUNE

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 the availability of top clearance for erection regitrodes from ESP top.
Always check the capacity & sufficient boom length of the crane.
b. To avoid the 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 the regitrode length, with facility
to fix 8–10 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 the top HV frame.
d. As briefed above, the bending of the regitrodes should be avoided. Also
while lifting the frame with regitrodes, the 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 the safe erection of first regitrode set, repeat the similar
procedure for erection of other regitrodes.
g. Once the 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.
 THERMAX LTD., ENVIRO DIVISION, PUNE

O. Alignment of regitrodes w.r.t. collecting plates

The field alignment (i.e. checking the gad 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). In the plan view, the position of the
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.

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.

Gas Passage Minimum clearance required between Regitrode pin to

Width collecting plate surface
At Top & Bottom Locations of At middle and other
approx. 1000mm of regitrode locations of
length regitrode
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 other 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 the collecting plate
surface or bend of the regitrode pipe. Hence, while doing field alignment, any
additional considerations should not be given on this point.
 THERMAX LTD., ENVIRO DIVISION, PUNE

e. The above field alignment readings are to be checked and recorded, for all fields of
ESP, as per the table no. 2.
f. Also while checking the alignment between collecting plate surface and regitrode,
following clearances should 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. A B C D E F A B C D E F
No. 1
No. 2
No. 3
No. 4
 THERMAX LTD., ENVIRO DIVISION, PUNE

Table No. 1: Format for recording collecting plate and regitrode alignment readings:

GP No. At Top of Field At Bottom of Field

E F E F
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18

Note: The above format of alignment reading recording is for 18 gas passages.
However, in case of more gas passage, similar format can be made and used.
 THERMAX LTD., ENVIRO DIVISION, PUNE

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 the 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 topside 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
 THERMAX LTD., ENVIRO DIVISION, PUNE

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 the 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 the 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 the 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 the dry run of crane, as briefed in collecting plate
erection. Further lifting of the nozzle assembly should be done only after
ensuring the 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.
 THERMAX LTD., ENVIRO DIVISION, PUNE

k. No man movements should be allowed below the area where erection work is in
progress.
l. Once the 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 the 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 that 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 the
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.
 THERMAX LTD., ENVIRO DIVISION, PUNE

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 the fields are filled with internals, the 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 the lifting equipment i.e.
chain blocks / tackles i.e. d–shackles, 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 the 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 the lugs welded on girders. Here the 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 the 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 the 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 the hopper lower portion, ensure the elevation of hopper outlet flange
(as per drawing) along with its water level.
k. After 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 the welding defects, kerosene test of hopper weld joints to be done,
to ensure the leak proof of 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, the 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).
THERMAX LTD., ENVIRO DIVISION, PUNE

o. For this purpose, refer the hopper level platform drawing sent separately.
p. While erecting the 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 the hopper level platform, take due precautions to avoid the
damages to the parts installed below hopper.
r. Ensure easy opening and closing of the hopper access door, after installation of
platform.
 THERMAX LTD., ENVIRO DIVISION, PUNE

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 the typical
sketches 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 the 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 the structure alignment, complete the structure welding as per
drawing and then erection & welding of monorail beam. Ensure that stoppers at
both free end of monorail structure 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 the 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 the erection area, during erection of monorail
& its structure.
 THERMAX LTD., ENVIRO DIVISION, PUNE

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) and monorail (erection & welding) if TR set are to be erected by
monorail.
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 the TR set base frame, as shown in referred drawing.
c. Place the TR sets on this base frame. Ensure that the correct rating TR sets are
installed at their respective fields. For this purpose always refer the ESP’s GA
drawing.
d. While erecting the 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 the TR sets at their position, fix the HV duct, as shown in the 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 the HV pipe to TR set –ve-
bushing. Otherwise this would result in failure if TR set’s – ve bushing and its stud.
h. To avoid the malfunctioning of ESP operation due to mis-alignment of HV pipe in HV
duct, always check & ensure that HV pipe is at center of the HV duct.
i. Ensure the seal welding of HV duct with penthouse top roof. This weld joint should
be checked for kerosene test.
 THERMAX LTD., ENVIRO DIVISION, PUNE

V. Erection & Alignment of Collecting Plate Rapping System

The erection of collecting plate rapping system should be started after completing the
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 to drawing sent separately.
d. Take the reference of the center of respective anvil beam and mark / transfer this
center on inner roof and penthouse top roof. Make the opening of 90mm diameter
w.r.t. these center points and position / install the 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 the rapper boot mounting, ensure that all rapper boot mounting top
flange are at same level.
Before welding the 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 the 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 needs to be rectified.

e. After completing the 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 the 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 the help of check-
nuts.
THERMAX LTD., ENVIRO DIVISION, PUNE

Similar procedure should be followed for all other rapper coils.

While erecting the collecting plate rapper coils, ensure that all rapper coils are installed
at same levels.
 THERMAX LTD., ENVIRO DIVISION, PUNE

W. Erection & Alignment of Regitrode Rapping System

The erection of regitrode rapping system should be started after completion of alignment
of support insulator and erection of penthouse top roof.

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 the reference of center of respective regitrode rapper rod clamp coupling and
mark / transfer this center on penthouse top roof, 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 the rapper boot mounting, ensure that all rapper boot mounting top
flange are at same level.
Before welding the rapper boot mounting assembly following points to be ensured –
• Distance of rapper boot mounting flange to inner roof top surface as shown in
attached sketch no. 067.
• Correct plumbness of rapper boot mounting assembly
• Center of rapper boot mounting in line with the center of respective anvil beam
and spirit level of anvil beam
• Spirit level of rapper boot mounting top flange
After ensuring the 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 needs to be rectified.

d. After completing the 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 the rapper coil with plunger, following 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 schematic
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 the help of check-
nuts.

Similar procedure should be followed for all other rapper coils.

While erecting the collecting plate rapper coils, ensure that all rapper coils are installed
at same levels.
 THERMAX LTD., ENVIRO DIVISION, PUNE

X. Erection & Alignment of Inlet GD Rapping System

The erection of inlet GD rapping system should be started after completing the 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 the inlet GD screen alignment and its locking with nozzle side /
bottom plates, fix the rapping channel arrangement on GD screen, as per the
reference drawing. For reference, refer the 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 the 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 the spirit level of rapper boot flange. Once correct alignment of rapper
boot is maintained, do the welding of boot mounting assembly with nozzle plate.
Ensure that all rapper boot flanges are at same level.
Before welding the rapper boot mounting with nozzle top plate, following points
should be ensured –
• Distance of rapper boot mounting flange to single end tapered coupling as
shown in referred drawing.
• Correct plumbness of rapper boot mounting assembly
• Center of rapper boot mounting in line with the center of respective single end
tapered coupling.
• Spirit level of rapper boot mounting top flange
After ensuring the 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 needs to be rectified.

e. After completing the 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 the 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.
THERMAX LTD., ENVIRO DIVISION, PUNE

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 the help
of check-nuts.

Similar procedure should be followed for all other rapper coils of inlet GD screen rapping
system.
While erecting the inlet GD screen rapping coils, ensure that all rapper coils are installed
at same levels.
 THERMAX LTD., ENVIRO DIVISION, PUNE

Y. Fixing of Warning Sign Boards and Mechanical Interlock System

• Warning Sign Boards

For safety precautions, the 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 Above Access Door
Warning Sign for High Voltage On TR set
Thermax Monogram On ESP Top

Along with the 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 the proper lock out of the
electrical system and de-energisation of the HV transformer rectifier sets, before
entering inside the ESP.
The system comprises the set of castle key & locks, such that unless the 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 earthing 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.
 THERMAX LTD., ENVIRO DIVISION, PUNE

DOOR INTERLOCK DIAGRAM : -

• Operational Philosophy :
For accessibility to ESP internals through the access door. The following sequence to
be followed.
THERMAX LTD., ENVIRO DIVISION, PUNE

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 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 & D1,D2,D3 3 nos.
interlock with TRCC on/off) (Lock without key)
3 Ground switch lock (For locking the grounding G1,G2,G3 3 nos.
switch to ESP earth position) (with key)
4 Transfer block assembly – A consists of 3-nos. G1,G2 ,G3 1 set.
lock without key & 1 no. master lock (`X’) with key &X
5 Key exchange box (Transfer block assembly –C) X1,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 B1=7 nos. 1 set.
& B2) Consist of 7 nos. & 4 nos. access door B2=4 nos.
locks with key each & 1 no. master lock (`X1’ & X1=1 no.
‘X2’ respectively) without key X2=1 no.
7 Chain type door locks with out key for access B 11 Nos.
doors (On ESP)
 THERMAX LTD., ENVIRO DIVISION, PUNE

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 the 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 the brief procedure to carry out the air leak test –
a. Install the 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 the 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 90–100mmWC.
i. Once the 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.

ONCE THE AIR LEAK TEST IS COMPLETED THE 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 idea on the
ESP assembly. This can help user to understand the ESP components pictorial
views, before its assembly and erection.
C A S I N G A S S E M B LY

Casing roof panels

To p G i r d e r s Side panels

Bottom Girders Casing Column

E S P TO P V I E W

TR Sets

Monorail Rigitrode
Rappers

Railing

Collecting
Rappers

Purge air
Fan

Nozzle
Rappers
P E N T H O U S E A S S E M B LY

Roof panel

Middle Beams

Side panels

Side Beam
Channels Penthouse Column

H O P P E R A S S E M B LY

Panels

Access
Door
Bypass chute

RAV &
Slide gate
HOPPER AND DUST DISCHARGE SYSTEM
Expansion
Bearing

Structure
Hopper
Platform Staircase

H O P P E R A S S E M B LY

Railing

Platform
Members

Grating

Tie
Beams
S TA I R C A S E A S S E M B LY

Penthouse
Landing
E n t r y o n To p

Nozzle level
Platform Railings

Stringers

Entry on Hopper
Level Platform

T Y P I C A L S TA I R A S S E M B LY

Farr side stair

Near side stair

Railing

Stringers

Step riser

Grating

Landing
I N L E T N O Z Z L E A S S E M B LY

S p l i t p a n e l s ( To p )

Inlet flange Side panels

Bottom Panels Casing opening

O U T L E T N O Z Z L E A S S E M B LY

Casing opening Split panels

(Top)

Outlet flange

Side panels

Bottom panels
PENTHOUSE INSIDE VIEW

Monorail Structure

T/R Sets

Collecting Boot mounting Support Insulators

M O N O R A I L S T R U C T U R E A S S E M B LY

Monorail Beam

Tie Beams

Column

Bracings
E S P E L E VAT I O N

Monorail structure

Penthouse T/R Sets

Access Door
ESP Casing

Inlet Nozzle Outlet Nozzle

Nozzle
Platform

Casing
Doors

Staircase

Structure

Hoppers

Hopper platform
RAV & Slide gate

The copyright of this document is the exclusive property of

T H E R M A X LT D . W i t h o u t p e r m i s s i o n i t m a y n o t b e c o p i e d o r
reproduced or delivered or made known to third parties.
 THERMAX LTD., ENVIRO DIVISION, PUNE

10. 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 the 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 the type of application and type of hoppers, the hopper heaters
are provided for ESP hoppers.
ii) The hopper heaters should be fixed on hopper side walls, as shown in the
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, the 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, the 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 the 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
the above 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 the ZSS are briefed in the above sketch.

E. Fixing of Vibrators for Hopper (if applicable)

For fixing the hopper vibrators, refer the drawing sent separately.

F. Fixing of Purge Air Blower

 THERMAX LTD., ENVIRO DIVISION, PUNE

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
Rectifier Unit
2
(Representative)
Control
3
Panel
(Representative)
4

5 To Remote On/Off

6 To Remote 4-20 mA indication

7 To Remote Alarm / Trip indication, HT On / Off

indications (Optional)
Refer following Sl. Nos. for above circled numberings, in detail.

Sl. No Cable Details Layout

1 Cable for Power Connections: Power cables should not to be mixed with
PVC Insulated, 650 / 1100 V Grade, any control cable (Sr.No. 3, 4 & 5)
Aluminum Conductor, Armoured cable.
(Size & details as per Project Rating)
2 Cable for Primary Voltage Feedback : Feedback cables should not to be mixed /
2C or 3C–2.5 sq. mm., PVC Insulated 650 bunched with Cables for Secondary
/ 1100 V Grade, Copper Conductor, Current & Voltage feedback & Cable for
Armoured Control Cable Alarm & Annunciation, i.e. Cable No. 3 &
4. This can be bunched with Power cable(
Sr.No.1)
3 Cable for Secondary Current & Voltage These cables to be laid separately and
Feedback : not to be mixed with power cables
4C-1.5 sq. mm., PVC Insulated 650 / 1100 (Sr.No.1) or Primary Voltage Feedback
V Grade, Copper Conductor, Overall cable (Sr.No. 2) or any other cable having
shielded with minimum 80% shielding potential higher than 30 V.
Armoured Control Cable
4 Cable for Alarm & Annunciation : To be laid separately and not to be
10C-2.5 sq. mm., PVC Insulated 650 / bunched with Power Cable (Sr.No.1) or
1100 V Grade, Copper Conductor, Primary Voltage Feedback Cable
Armoured Control Cable (Sr.No.2) or Cable for Secondary Current
& Voltage (Sr.No. 3) or any other cable
having potential higher than 50 V
5 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 &
1100 V Grade, Copper Conductor, instrumentation cable
Armoured Control Cable
6 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 cable having potential higher than 30 V
V Grade, Copper Conductor, Overall
shielded with minimum 80% shielding
Armoured Control Cable.
7 Cable for Remote Alarm / Trip indication, Not to be mixed / bunched with any
HT On / Off indications (Optional) power cable & instrumentation cable
*C-2.5 sq. mm., PVC Insulated 650 / 1100
V Grade, Copper Conductor, Armoured
Control Cable
(* No. of cores as required, Pl. refer the
project specific schematic drawing)
 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.
 Figure 1

≥300 mm

≥30mm ≥100mm
Metal Cable Tray

Power Cables: Control Cables:

Signal Cables:
(Typically 415 V / 230 V) (Typically 230 V 110 V)
(Typically 24 V / 4-20 mA,
Control Panel Supply Relay Supply
Instrumentation cable)
Fan Motors Supply Contactor 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
 THERMAX LTD., ENVIRO DIVISION, PUNE

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 the ESP earthing grid and ESP control room earthing must be independent
from plant earthing. No plant 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) The 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 the 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 25 x 3 MM. STRIP
Hopper Level Platform
10 Rapper Distribution Panel 25 x 3 MM. STRIP
THERMAX LTD., ENVIRO DIVISION, PUNE

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

xi) During ESP operation, the 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.
 THERMAX LTD., ENVIRO DIVISION, PUNE

11. ESP Pre–Commissioning Checklists

The pre commissioning checklists are attached with this separately. All the 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 the attached
checklist is completed.
 ESP's Mechanical Completion Check Lists
Name of Customer:
Plant / Site Location:
Customer PO No.:
Thermax OC No.:
Name of Thermax Representative:

Checked & Witnessed

Sl. Completion Date
Check Point Description by
No.
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
1 Erection of ESP casing panel & column, top & bottom girder as per drawing w.r.t. ESP centerline and its inspection
protocol (for plumb, axial & diagonal measurements).
2 Inspection of weld joints. Kerosene leak test of all weld joints.. All weld joints should be free from for left out welding /
welding defects like blow holes, welding cracks etc.
3 Removal all temporary supports provided for casing erection / welding purpose, after ESP alignment and before ESP box-
up.
Inlet Nozzle with Perforated Sheets
1 Inspection of inlet nozzle assembly & its installation with perforated sheets as per drawing.
2 Inspection of weld joints. Kerosene leak test of all weld joints.. All weld joints should be free from for left out welding /
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 Inspection of weld joints. Kerosene leak test of all weld joints.. All weld joints should be free from for left out welding /
welding defects like blow holes, welding cracks etc.
3 Alignment of outlet nozzle inlet flange (plumbness and diagonal).
 Checked & Witnessed
Sl. Completion Date
Check Point Description 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 Inspection of weld joints. Kerosene leak test of all weld joints.. All weld joints should be free from for left out welding /
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.
6 Installation of hopper vibrators (as per drawing), if applicable.
7 Installation of hopper heating pad, (as per drawing), if applicable.
8 Installation of Rotary Air Lock Valve and Slide Gate below hopper (as per drawing), if applicable. Check the flange to
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.
5 Check the straightness & plumb of installed collecting plate, in its free hanging condition. All collecting plates should be
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
1 Inspection of top HV frame erection and its alignment (level & positioning w.r.t. adjacent collecting plate rows). Ensure that
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.
3 Check the gap between collecting plate and regitrode, using GO / NO GO type gauge. All temporary locking / supports of
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.
Collecting Plate Rapping System
1 Alignment (verticality / plumb) of rapper rods.
 Checked & Witnessed
Sl. Completion Date
Check Point Description by
No.
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.
2 Grounding of the rapper rods.
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).
5 Sealing of rapper rods, using hypalon boot and clamps.
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.
3 Level 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.
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.
 Checked & Witnessed
Sl. Completion Date
Check Point Description by
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 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
1 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 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.
 THERMAX LTD., ENVIRO DIVISION, PUNE

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 • Operational checking of
wiring, as per drawing hopper heaters w.r.t.
Thermostat setting
• Checking of RDP panel • Checking of TR panel • Operational checking of
(Resistance / Continuity for lamp load insulator heaters w.r.t.
checking) as per designed Thermostat setting
matrix.
• Checking of MTP panel and its • Checking of TR set • Operational checking /
lamp load testing for Open Circuit & calibration of hopper level
Short Circuit test controllers / Hopper
Vibrators
• Checking of MTP panel with all • Air load test • Operational checking of
rappers and rapper lift checking Purge Air Blower
• Removal of Structural Bearing locking

The approx. time required for pre-commissioning is 7 days.

Some of the above pre–commissioning activities are briefed below –

I. Gas Distribution Test

For efficient & desirable operational performance of ESP, the gas flow needs to be
uniform across the cross section of ESP. To check the gas flow pattern inside ESP,
the 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 the ESP
with the help of anemometer.
• The velocity readings are to be taken at approximately 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 the 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.
For reference, the attached format can be referred.
• After conducting the GD test, the velocity readings shall be compiled and analysed
w.r.t. average velocity. For correct gas flow pattern –
THERMAX LTD
ENVIRO DIVISION
PRECOMMISSIONING REPORT (ESP)
Gas Distribution Report Format
THERMAX
Format: T-EPD-SR-F-023

Customer:
Plant Location:
Date: Time: From Hrs To Hrs

Gas Passage
Approx. Height 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18
Inspection Door Side

from bottom
7.0 m
6.5 m
6.0 m
5.5 m
4.5 m
3.5 m
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

 Within the treatment zone, near the inlet / outlet faces of the ESP field, minimum
85% of velocities shall be within 1.15 times average velocity and minimum 99% of
velocities shall be within 1.40 times average velocity.
In case, the gas velocity does not confirm the above standard, the diverter plates
and / or perforated plate hole blocking is to be done to confirm the above standard.
To achieve correct gas distribution, the test might be required to be done several
times.

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 operated before ESP’s GD test. Before
conducting the GD test, the ID and / or FD fans must be kept ON till such time that
the 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, the rapping system
of ESP should be kept ON. This is very much essential for safety of the
representatives conducting GD test.
• During GD test, the 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 the 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.
• All the ESP 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, the 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, the 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 1Ω.

IV. Checking of RDP & MTP panel (Resistance / Continuity / Matrix / Lamp
Load / Operation)
• To check the healthiness of RDP and its components
• To check the healthiness of MTP and its components, alongwith its functioning, as
per requirement
• To check the rapper panel functioning
• To set the lift of rapper plunger, for respective rapper coil

V. Checking of TR set oil BDV value.

Several times the Transformer Rectifier sets are stored for longer period i.e. for more
than six months, at sites. Under such circumstances, the 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 the 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 bottom 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 the container and rinse the container
with this oil. Once again clean the oil-tapping valve opening, with this oil.
Repeat this procedure for 2–3 times more, so that the oil container / bottle is
thoroughly cleaned with the TR set oil.
d. Then collect the oil sample in the cleaned oil container. While collecting the oil
sample, do not allow entry of 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 little 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 the 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 the healthiness of ESP fields.
• Air load test is to be done after completing ESP’s all inside activities.

The formats of the pre–commissioning reports are attached herewith separately.

 THERMAX LTD PRECOMMISSIONING REPORT
ENVIRO DIVISION

Page 1of 7
THERMAX

Client:- Application:-
Client’s PO No.:- Thermax’s OC No:-
Format: T-EPD-SR-F-023 Rev.: 1
T/R SETS & TRCC DETAILS

Field No. Make Serial 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:

DESCRIPTION MINIMUM FIELD 1 FIELD 2 FIELD 3

REQUIRED (IN MΩ)
Primary To Earth 50
(LT To Earth)
Primary To Secondary 500
(LT To HT)
Secondary To Earth 100
( HT To Earth)

TRANSFORMER OIL B.D.V. TEST RESULT

Note: Gap between electrodes = 2.5 mm and Minimum Required B.D.V = 50 kV (For mineral base oil)
Ambient Temp: - ºC

Field 1 Field 2 Field 3

Average

Date:
Name:
Sign:
COMPANY: THERMAX CUSTOMER CONSULTANT
 THERMAX LTD PRECOMMISSIONING REPORT
ENVIRO DIVISION

Page 2of 7
THERMAX

Client:- Application:-
Client’s PO No.:- Thermax’s OC No:-

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:
COMPANY: THERMAX CUSTOMER CONSULTANT
 THERMAX LTD PRECOMMISSIONING REPORT
ENVIRO DIVISION

Page 3of 7
THERMAX

Client:- Application:-
Client’s PO No.:- Thermax’s OC No:-

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% tolerance.

Date:
Name:
Sign:
COMPANY: THERMAX CUSTOMER CONSULTANT
 THERMAX LTD PRECOMMISSIONING REPORT
ENVIRO DIVISION

Page 4of 7
THERMAX

Client:- Application:-
Client’s PO No.:- Thermax’s OC No:-

TESTING OF EARTHING STATIONS

Earth Earth Resistance (In mΩ)

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

Earth Resistance of Grid = Ω

Note: Earth grid resistance should be less than 1Ω

MEGGER TEST OF FIELD

This test should be carried out by megger of 5kV

Bus Section No. Insulation Level (MΩ)

1
2
3
4
5
6
7
8
9
10

Date:
Name:
Sign:
COMPANY: THERMAX CUSTOMER CONSULTANT
 THERMAX LTD PRECOMMISSIONING REPORT
ENVIRO DIVISION

Page 5of 7
THERMAX

Client:- Application:-
Client’s PO No.:- Thermax’s OC No:-

T/R SETS: AIR LOAD TEST

This test is to be carried out through TRCC panel only.

MA Field 1 Field 2
Set Primary Secondary Spark Primary Secondary Spark
Point Voltage Current Voltage Current Rate Voltage Current Voltage Current Rate
(V) (A) (kV) (mA) (V) (A) (kV) (mA)

MA Field 3
Set Primary Secondary Spark
Point Voltage Current Voltage Current Rate
(V) (A) (kV) (mA)

Date:
Name:
Sign:
COMPANY: THERMAX CUSTOMER CONSULTANT
 THERMAX LTD PRECOMMISSIONING REPORT
ENVIRO DIVISION

Page 6of 7
THERMAX

Client:- Application:-
Client’s PO No.:- Thermax’s OC No:-

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:
COMPANY: THERMAX CUSTOMER CONSULTANT
 THERMAX LTD PRECOMMISSIONING REPORT
ENVIRO DIVISION

Page 7of 7
THERMAX

Client:- Application:-
Client’s PO No.:- Thermax’s OC No:-

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:
COMPANY: THERMAX CUSTOMER CONSULTANT
 THERMAX LTD., ENVIRO DIVISION, PUNE

13. Commissioning Activities

Following sequence should be followed while commissioning of ESP.

1. Prior to ESP commissioning all pre commissioning and thermal insulation

application works must be completed in all respect.
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.
 THERMAX LTD
ENVIRO DIVISION

Page 1of 3 THERMAX

Format: T-EPD-SR-F-025 Rev.: 1

COMMISSIONING REPORT
1. Product : ELECTROSTATIC PRECIPITATOR

2. 2.a) Clients name and Location :

2.b) Client’s PO No. & date :

2.c) Thermax O.C. No. :

3. Application :

4. ESP Model :

5. Fuel used :

6. ESP Parameters

Parameters UoM Inlet Outlet

Design Actual Design Actual
Gas Flow AM3 / Hr

Inlet Dust load gm / NM3 NA NA

Out let Dust mg / NM3 NA NA

concentration
Temperature °C

7. Load on customer’s equipment :

against rated load

8. TR set Operational Readings :

Field No. Primary Side Secondary Side Sparks

per min.
Voltage in Current in amps Voltage in kV Current in mA
Volts

Field 1

Field 2

Field 3
 THERMAX LTD
ENVIRO DIVISION

Page 2of 3 THERMAX

Format: T-EPD-SR-F-025 Rev.: 1

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 :
iv) Current Drawn in amps :

E. Compressor :

i) Make and Model :

ii) Drive make and model :
iii) Performance :
iv) Current Drawn in amps :

11. Power Supply (Customer’s scope) :

i) Supply Voltage :
ii) Fluctuation, if any :

12. Control Room :

i) Air Conditioned :
ii) Pressurised :
iii) Dusty / Clean :
 THERMAX LTD
ENVIRO DIVISION

Page 3of 3 THERMAX

Format: T-EPD-SR-F-025 Rev.: 1

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.

18. Name of the person & signature :

witnessing Commissioning trials.

19. Name of the person & signature :

handing over unit

20. Name of the person & signature :

taking over unit.

Enclosure(s) :
THERMAX LTD
ENVIRO DIVISION
PMT Complex, Behind PCMC Building
Mumbai-Pune Road, Pimpri THERMAX
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.
THERMAX LTD
ENVIRO DIVISION
PMT Complex, Behind PCMC Building
Mumbai-Pune Road, Pimpri THERMAX
PUNE 411 003
ACCEPTANCE REPORT
Page 2 of 2

(F) Corrective Work:

Sl. Nature of Work Responsibility Scheduled Date

No. of Completion

Participant Name Company Date Signature

1.
2.
3.
 THERMAX LTD., ENVIRO DIVISION, PUNE

14. Precautions for smooth & trouble free functioning of ESP

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:
2.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.
2.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 along 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
THERMAX LTD., ENVIRO DIVISION, PUNE

biomass-fired boilers. Routine maintenance is must with proper spares back up in

order to keep the system available and operational.
2.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.
2.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 &
 THERMAX LTD., ENVIRO DIVISION, PUNE

maintenance manual. Start interlock for ID fan shall be provided such that ID fan
should not start unless all the access doors is closed.
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 fired boiler E.S.P.

Sl. Item description

No.
1. Two No. Of pneumatic vibrators should be provided for each hopper from outside. The
vibrators should be mounted in bottom 1/3rd of the hopper on opposite sides.
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.
6. The bypass chute shall be provided with blind flange. (Minimum size 400-mm dia.) except
for trough hoppers.
7. Hoppers shall have large poking holes of minimum 100 NB size to avoid dust bridging
 THERMAX LTD., ENVIRO DIVISION, PUNE

Following interlocks are incorporated in the design, and to be ensured at site.

Sr. Equipment / Instrument Signal Action

No. Parameter
1. Rotary Air Lock valves provided Alarm & Indication in ACP. Trip respective
below I&II Field Hoppers—Trip Trip signal is taken from zero TR SET.
speed switch(This zero speed Signal to DCS
switch is fixed near Rotary Air
Lock Valve Driven end )
2. Rotary Air Lock valves - Alarm & Indication in ACP. Trip respective
Over load relay Trip. TR SET.
Signal to DCS
Potential free contacts of Trip Trip Boiler.
3. If RAV faults persist for 2 hrs. relay will be provided in Signal to DCS
ACP for alarm & indication +
tripp signal to Boiler.
4 Dust conveying system shall be ON Potential free contact for tripping All TR SETS, all
all the time. the all TR SET, all RAV. RAV shall trip.
If dust conveying system
trip/stopped.
Hopper Heater (provided to keep Alarm &Indication in ACP. Trip Hopper
5 the ash hoppers hot to increase the heater.
flowability of ash- Normally, used to Signal to DCS
be started before 4 hrs of Boiler
start up) Temperature High.
6. RTD to be mounted in each Alarm & indication in ACP, Trip respective
Hopper, with TIC in ACP. Hopper Potential free contact for tripping TR SET.
Temperature Very High the Boiler. Signal to DCS.
Trip Boiler.
7. Transformer Sets (T.R.SET) Trip. Alarm &Indication in TRCC. Signal to DCS
Potential free contact to DCS.
8. Hopper Level High.(Level probe Alarm &Indication in ACP. Trip respective
provided at about 60%of total Immediately Trip the TR SET.
hopper height distance below the corresponding Transformer sets.
collecting plates ) Potential free contact in ACP for Signal to DCS
DCS signal.
9. Hopper Level High alarm persists Potential free contacts in ACP to Trip Boiler.
for 1 hr wire the same for Boiler Signal to DCS
Tripping/Stopping.
10. In case Inlet temp. Sensed by TE Alarm & Indication in ACP, Trip respective
increases above set point. potential free contact for DCS TR Sets.
TE to be mounted in the inlet duct signal Signal to DCS
of ESP.
THERMAX LTD., ENVIRO DIVISION, PUNE

I D FAN interlock. Potential free contacts in ACP, Trip I D FAN.

11 If RAV or Screw conveyor stopped / Alarm & Indication in ACP Signal to DCS.
tripped. &potential free contact to trip the
ID FAN.
Rapping system shall be ON all the ID Fan ON potential free contact
12. when ID FAN is running irrespective to MTP.
of ESP is charged or not.
13. Purge Air System Interlock If Purge air system is not Audio Visual
working then trip the T/R sets. Alarm

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.
 THERMAX LTD., ENVIRO DIVISION, PUNE

15. Safety Risk Assessment for ESP Activities

The safety risk assessment for ESP erection and commissioning is attached with this
separately.
All the needed precautions, given in the risk assessment should be adhered while doing
erection and commissioning of ESP.
 RISK ASSESSMENT FOR ESP ( ELECTROSTATIC PRECIPITATOR) INSTALLATION
Safety Risk Assessment Document (ESP) No.: TL/ENV/ESP/Safety/001 Rev 0

Sl.
Activities Hazards Safety Precaution Responsibility
No.
a) Use of PPEs like safety shoes, Hand gloves, Safety helmet Contractor & Customer
b) Use of catagorised skilled personal Contractor & Customer
a) Fall / slip of objects due to inadequate c) Safety introduction to all workmen & supervisors. The emergency contact nos.,
handling facilities like Fire / Ambulance / Nearest Hospital / Security are to be made available at all
Thermax Engg.
locations like site office / ground assembly area / erection area and also with site
engineers / contractor supervisors
Unloading of a) Safety instructions are to be followed during unloading of material. Thermax HO
1 Thermax HO
materials to send the safety instruction / risk assessment to sites well in advance.
b) Damages to the material due to not following
the safety instructions a) Special safety / unloading instruction for collecting plates / emitter electrodes /
Thermax HO
support & shaft insulator / GD screens are to be circulated in advance.
a) Unloading instructions to be sent to site alongwith material. Thermax HO
c) Use of inadequate / wrong / undersize material a) Use of correct size tools / correct capacity equipment for unloading the
Contractor & Customer
handling tools / equipment material; b)
a) Use of PPEs; b)Follow safe material handling procedure; c) Use of proper
a) Caught in between finger / foot injuries material handling tools & tackles. / Use of catogarised skilled manpower / Use of Contractor & Customer
correct tools / tackles / equipment for stacking the material
Storage / stacking of
2
materials Use of suitable wooden sleepers, supports to avoid fall of stacked material. /
b) Fall of ESP material due to improper stacking,
Provide sufficient cover like temporary shed / tarpaulin to avoid the damages to Contractor & Customer
resulting in to accidents and damage to material
the material due to dust / rain.
c) Gas Storage facility LPG / Acetylene gas storage facility
All lifting material to be tested for their capacity before taking them in to use. Test
a) Breakage of chain sling / wire rope & manila
certificate to be obtained from competent person. This is required as per factories Contractor & Customer
rope
act 1948.
Shifting of materials
to site (Manual &
3 a) Breakage of chain sling / wire rope & manila All lifting material / tools / tackles shall be checked periodically, for any defects
mechanical material Contractor & Customer
rope those arises during its use and stop its using if any defects found
handling equipment)
i) Verification of loading point of hydra / chain pulley block / test certificates of wire
Contractor & Customer
b) Overloading of equipment during lifting ropes
ii) Identification / marking of weight on the job being lifted Contractor & Customer
Sl.
Activities Hazards Safety Precaution Responsibility
No.
Contractor & Customer
c) Inadequate lift hook position ( Vertical & Proper lifting hooks are to be considered during design stage and same to (Check the marking on the
horizontal lifting) be provided during fabrication stage. component in place of
lugs.)
i) To avoid such type of dangerous unsafe acts, use of mobile phones should be
Shifting of materials
f) Accident or Damages to the material while avoided strictly. Also un-necessary communication with operators must be Contractor & Customer
to site (Manual &
3 lifting due to lack of focus on the job (e.g. talking avoided.
mechanical material
over mobile while operating crane / hydra / forklift ii) The material handling equipment's like crane, hydra, forklift must be operated
handling equipment) Contractor & Customer
/ winch etc.) / or not using of categorized skilled by AUTHORIZED LICENSE HOLDER DRIVERS ONLY.
manpower iii) Alcoholic consumption strictly prohibited during working hours. at site operating
Contractor & Customer
crane and other material handling equipment / vehicles.
Ensure that the approach road is clear while shifting the heavy materials like
Contractor & Customer
collecting plate crates / assembled components
a) All electrical cables are to be laid down safely either underground or overhead
a) Unsafe practice of cable laying from electrical Contractor & Customer
and through pipe conduit.
panel to site distribution board.
b) Safety sign to be displayed for caution, at all such location. Contractor & Customer
a) Main distribution board ELCB, of sufficient capacity / rating, should be provided
Contractor & Customer
with TPN facility, near ESP erection site.
b) Cable extension boards should be used. Contractor & Customer
Electrical connection
4 for erection / ground b) Unsafe practices of cable connections / joints c) Proper earthing should be provided for all electrical appliances being used at
Contractor & Customer
assembly work (hand lamps / tools / earthing) site. Earthing points to be checked and ensured.
d) All welding machines / other electrical tools are to be tested at site (for megger Contractor & Customer /
& current) for correct current rating. Thermax
e) Proper safe cover to be provided to all electrical appliances / boards specially in
Contractor & Customer
rainy season
b) Unsafe practices of cable connections / joints f) provide sufficient fire extinguisher / sand buckets near main DB & welding
Contractor & Customer
(hand lamps / tools / earthing) machines.
a) Uneven ground floor resulting slipping of Level the ground by back filling the soil at least 8-10 days prior to ground
Contractor & Customer
material during assembly assembly work, to avoid delay in activity.
a) Do not keep the flammable items (e.g. acetylene or LPG cylinders) near
Contractor & Customer
welding / cutting area.
Ground assembly
5 b) Welding sparks / fire /electrical shock causing b) Ensure the availability of fire extinguisher (CO2 or water / sand) or sufficient
work Contractor & Customer
fire hazards and damages to material & leading water while doing the hot work nearby flammable material.
to accidents
c) Ensure that the surfaces being welded are in dry condition. Also ensure that the
Contractor & Customer
welder is not over sweated which can cause accident due to electrical shock
Sl.
Activities Hazards Safety Precaution Responsibility
No.
a) Use of correct size cutting sets / cutting nozzles / back fire arrestor to be done.
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. Contractor & Customer
c) Accidents due to gas cutting / back fire /
Use proper hose pipe with standard colour coding and proper hose clamps to be
leakage of gas
used to connect the hoses.
b) Ensure the availability of fire extinguisher or sufficient water while doing the hot
Contractor & Customer
Ground assembly work.
5
work d) Accidents due to grinding sparks / eye injuries Use of PPEs like hand gloves, safety goggles, electrical appliances with proper
Contractor & Customer
/ fire / electrical shock earthing should be used.
e) Accidents causing to hand / finger injuries Use of PPEs like hand gloves, safety goggles, proper tools like wooden sleepers,
Contractor & Customer
during hammering / fitting packings while doing the work.
f) Accidents due to in-sufficient temporary
supports to component causing fatal accident / Use of sufficient support to avoid falling of component being assembled.
damages to material
Adequate safety precautions like are to be taken - i) Guy ropes, ii) Verticality of
a) Fall of derrick / fall of lifting arrangement & Contractor, Customer,
derrick after loading, iii) Barricade the area while erecting derrick, iv) Experienced
lifting support arrangement Thermax Engineer
& skilled riggers need to be engaged for derrick erection
a) Use of PPEs Contractor & Customer
b) Follow safe material handling procedure Contractor & Customer
b) Hand and foot injuries
c) Use of proper material handling tools & c) tackles Contractor & Customer
d) Periodic safety training Contractor & Customer
a) Provide adequate space for ground assembly of components. Contractor & Customer
Contractor, Customer,
b) All ground assemblies to be done on proper leveled platform
Thermax Engineer
c) Accidents resulting in loss of man-days and
Ground assembly c) Use of proper lifting tools / tackles (with test certificates) Contractor & Customer
6 affecting equipment performance due to
work Contractor, Customer,
inadequate facility / arrangement for material d) Adherence to the sequence of erection, alignment & welding
Thermax Engineer
being lifted
e) Ensuring sufficient lifting lugs for material being lifted Contractor & Customer
e) Ensure the dry run of the material handling equipment, before lifting the
material.
Contractor, Customer,
Thermax Engineer (Not
d) Fatal accident due to not using proper lifting
a) Under any circumstances, use of lifting frame & assembly jig must be ensured, following the safety
frame / tools / locking arrangements for material
as per Thermax drawing. precaution, will affect the
being lifted.
ESP completion schedule
and performance of ESP.)
Sl.
Activities Hazards Safety Precaution Responsibility
No.
a) The work group / supervisor should be briefed on the equipment knowledge / Contractor, Customer,
activity knowledge. Thermax Engineer
b) For effective communication, arrange meeting for allocating responsibilities, Contractor, Customer,
e) Accidents due to lack of knowledge of
Ground assembly before commencing the work. Thermax Engineer
6 equipment & poor communication / inadequate
work Contractor, Customer,
work procedure & wrong erection sequence c) Follow the sequence of mechanical installation.
Thermax Engineer
d) Always responsible, authorised person must be available outside ESP, while
workmen are working inside ESP.
a) Use of PPEs i.e. safety belt, helmet, safety shoes, hand gloves, safety goggles
Contractor & Customer
etc.
a) Fatal accident / permanent disability
b) Provision of proper scaffolding and ladder arrangement for working people at
Contractor & Customer
higher elevation.
a) Provide proper ladders to have approach to ESP columns / girders after
Contractor & Customer
b) Inadequate facility to reach at high elevation, erection. Use of fall arrestor for the working men at height.
resulting into fatal accident 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.
a) No man movements, on ground / lower elevation, is allowed while any work
Contractor & Customer
7 Working at height (cutting / erection / material lifting / fitting) is going on at higher elevation.
c) Falling of tools / scrap - debris / erection b) All tools, being used at high elevation should be tied to job, with proper chain,
Contractor & Customer
material 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 while
b) Continuous restless work, which can affect workmen fitness, should not be
working at height Contractor & Customer
allowed.
e) High wind flow causing disturbance in work
a) No work should commence, if heavy windflow affects in safe work conditions Contractor & Customer
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'.
a) Improper lock out while working with electrical
live power supply during installation / sequence b) For cable termination, the sequence shall be followed from main equipment to
of cable termination supply point e.g. MCC / ACP to TRCC or TRCC to TR set. First TR set cable Contractor & Customer
termination to be done followed by termination at TRCC and then at MCC / ACP.
8 Electrical Installation a) While pulling the cables vertically upwards, sufficient workmen to be deployed
Contractor & Customer
at various elevation with use of PPEs.
b) Improper way of cable pulling
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 (hand lamps /
b) Proper earthing should be provided for all electrical appliances being used at
tools / earthing) Contractor & Customer
site.
Sl.
Activities Hazards Safety Precaution Responsibility
No.
a) No hot work to be done near electrical / instrument items, without putting proper
Contractor & Customer
cover on the items.
d) Hot work (gas cutting / welding / heating etc.)
Contractor, Customer,
near electrical / instrumentation items like cables, b) Follow the installation sequences
Thermax Engineer
TR sets, Heaters, Level sensors etc.
Contractor, Customer,
c) Equipment awareness to be given to the workmen
Thermax Engineer
Use of proper tools / tackles for cable termination / crimping. All cable are to be
8 Electrical Installation
Accidents due to improper crimping / workman terminated with use of lugs. All activities are to be done by categorized skilled
ship / inadequate measuring instruments 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
a) Proper work permit must be obtained ensuring power lock out / men on work at Contractor, Customer,
panels, before entering ESP inside. Thermax Engineer
Contractor, Customer,
b) Use of PPEs must be ensured before entering inside ESP for GD test.
Thermax Engineer
c) Before entering inside ESP, ensure that there is no dust passing through ESP.
a) Serious accident due to inhalation of dust Contractor, Customer,
This can be done by running the ID fan till stack is clean visually, before entering
inside ESP (Confined Space) during ESP GD test Thermax Engineer
inside ESP.
Contractor, Customer,
d) Proper communication tools must be used while conducting GD test.
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,
Pre-Commissioning /
instrumentation, mechanical works i.e. entry in
9 Commissioning Proper work permit must be obtained ensuring power lock out / men on work at Contractor, Customer,
confined space (narrow area inside ESP), non-
Activities panels, before entering ESP inside. Thermax Engineer
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.
d) Chances of explosions inside ESP i.e. due to a) Install CO analyzer. ESP TR sets tripping interlocking to be incorporated if CO
Contractor & Customer
CO accumulation inside ESP / carry over of un- level is more than 2%
controlled, unburned inside ESP / improper b) In case if ESP ID fan is tripped for any reason, ESP purge air blower should be
Contractor & Customer
sequence of plant start up or shut down - All switched OFF immediately.
resulting into ESP internal damages / ESP b) Arrest all false air leakages inside ESP which supply oxygen to the fire. The
damage / Fatal Accident / Heavy losses to sources of false air leakages might be from Rotary Airlock Valves, Inspection Contractor & Customer
property Doors, Hopper By-pass chute
Sl.
Activities Hazards Safety Precaution Responsibility
No.
Inhalation & Exposure of dust, mist, fumes,
a) Wear suitable PPEs Individual
gaseous
Working in hazardous b) Before entering around / inside equipment, measure hazardous gases (CO) Individual (Customer to
10
zone 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
 THERMAX LTD., ENVIRO DIVISION, PUNE

16. 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.
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.
2. The location of the sampling points shall be selected at the inlet duct or stack, in
such a way that there is sufficient straight length in up stream or down stream of the
ESP.
Approximately the sampling points should be located, preferably eight times duct
diameter at down stream and two times duct diameter at up stream. 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)
 THERMAX LTD., ENVIRO DIVISION, PUNE

d. Dust Concentration (gm/Nm3)

e. Moisture content in flue gas (in % vol. / vol.)

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 the ESP, each three samples shall be taken and the 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 the fuel, the fuel samples shall be
collected for the fuel being fired at the time of sampling.
8. To conduct the 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 the testing should be sent to testing laboratory
for further testing and analysis. Then the final results / analysis and calculations shall be
submitted.
Following is the standard template, used to tabulate the ESP test data, actual Vs
design. This is for reference only.

Sl. Temperature in Gas Flow in Inlet Dust Outlet Emission in

No ºC (At ESP AM³/hr Concentration mg/NM³
inlet) in gm/NM³
Design Actual Design Actual Design Actual Actual Design
1
2
3
Avg.