STANDARD OPERATING PROCEDURE

PPGCL Super Thermal Power Plant

3 X 660 MW.
FIELD SOP FOR ESP LINE CHARGING.
Document No.: Revision No.: 01
Effective Date: Page 1 OF 8
PMPL/AHP/SOP/11 Revision Date:

ESP LINE UP AND CHARGING

1. Introduction:
Each boiler, equipped with two double room, five electric fields and high efficiency electrostatic
precipitator of guaranteed efficiency 99.898%, has a total of 16 hoppers. Each hopper adopts a
mode of electric heating and its reserve capacity is designed by not less than 8-hours ash content
when the boiler MCR working condition is maintained. The outputs of fly ash conveying system
and equipments meet the maximum ash exhaust content of boiler MCR and still maintain
sufficient allowance.
2. Technical data:

Type Bharat Heavy Electricals Limited.

Type of Precipitator FAA-8x45-2x76165-2

Type of coal Design Coal Worst Coal

Gas flow rate 947.5 m3/sec 1029.24 m3/sec

Gas temperature 131°C 137°C

Inlet Dust concentration 48.9 gm/Nm3 49.1 gm/Nm3

ESP efficiency 99.897% 99.898%
Velocity of Gas Inside ESP 0.63 m/s 0.68 m/s

Treatment Time 50.27 sec. 52.89 sec.

Pressure drop across the precipitator for
25.0 mm WC
design condition
No. of Precipitator per unit 6 Nos.
No. of Gas Path per ESP 1 No.

No. of Fields in series in each gas Path 8 Nos.

Collecting Electrodes:
No. of rows of collecting electrodes per field 39
No. collecting electrodes per field 234
No. collecting electrodes arranged in each row
6
per field

Prepared by (PMPL): Reviewed by (PMPL): Reviewed by (PPGCL): Approved by (PPGCL):

Signature: Signature: Signature: Signature:

Name: Name: Name: Name:

Desg.: Operation In-Charge Desg.: Site In-Charge Desg.: Operation In-charge Desg.: Plant Head
 STANDARD OPERATING PROCEDURE
PPGCL Super Thermal Power Plant
3 X 660 MW.
FIELD SOP FOR ESP LINE CHARGING.
Document No.: Revision No.: 01
Effective Date: Page 2 OF 8
PMPL/AHP/SOP/11 Revision Date:

Total no. of collecting plates per boiler 11232

Nominal height of collecting plate 16.5 meters
Nominal length of collecting plate 750 mm

Emitting Electrodes:

Type Spiral with hooks

Size 2.7 mm dia.

No. of electrodes in the frame forming one row 72

No. of electrodes in each field 2736

Total no. of electrodes per Boiler 131328

Total length of electrodes per field 14052

Plate / wire spacing 200 mm (across the ESP)

Rappers for Collecting Electrodes:
One drop hammer per row collecting electrode
No. and type of rappers
having a Collecting surface of 148.5 m2
Rapper size 4.9 Kg

Location At the bottom of collecting electrodes

Rappers for Emitting Electrodes:
Approximately one drop hammer for two rows
No. and type of rappers
of electrodes
Rapper size 3.0 Kg

Frequency of rapping 10 raps per hour

On middle frames of emitting system
Location
Framework
Rapping of gas distribution system:
Quantity 2 Nos.
Geared motor 0.5 HP, 1.1 rpm, 3 phase, 415 V
Rating
50 Hz, AC
Location On the GD housing

Prepared by (PMPL): Reviewed by (PMPL): Reviewed by (PPGCL): Approved by (PPGCL):

Signature: Signature: Signature: Signature:

Name: Name: Name: Name:

Desg.: Operation In-Charge Desg.: Site In-Charge Desg.: Operation In-charge Desg.: Plant Head
 STANDARD OPERATING PROCEDURE
PPGCL Super Thermal Power Plant
3 X 660 MW.
FIELD SOP FOR ESP LINE CHARGING.
Document No.: Revision No.: 01
Effective Date: Page 3 OF 8
PMPL/AHP/SOP/11 Revision Date:

3. Principle of Operation:The principle of dust collection in an ESP is as follows:When

passing through the high voltage electrostatic fields, dust particles in the gas is charged by
colliding with positive ions, negative ions and electrons or in the ion dispersion movement. The
particles with electrons and ions on them will then move, under the influence of the electric
force, toward and later accumulate on the electrodes of opposite polarity. By means of rapping,
the layer of dust particles on the electrodes will be dislodged into the bottom hoppers.Practice
that shows the higher the strength of electrostatic field, the more effective an ESP will be, and
that it is preferable to have an ESP operating with negative corona. Therefore, our ESPs are
designed in the structure of high voltage negative corona electrodes.
a) Mechanical Portion

Collecting System:
The collecting system consists of suspension devices, collecting plates, shock bars, etc. Collecting
plates are shaped with steel coils on special rolling machines. The curtain of several collecting plates
linked together must have good rigidity, and its flatness should be kept within the specified range so
as to assure the limited deviation of distance between the collecting and emitting electrodes.
Emitting System:
The emitting system consists of suspension devices, top horizontal beam, vertical beam,
upper, middle and lower frames, discharge wires, etc. The discharge wires are manufactured
by special equipment. Two types of discharge wires can be offered by our plant, i. e tubular
barbed wire and spiral wire, both being ESP’s key parts.
Emitting suspension devices are used to support the whole emitting system from the top
girders and to connect with high voltage of negative polarity. The function of the planar
structure combined by vertical beam, top horizontal beam, angle iron, etc. is to fix the upper,
middle and lower frames and the emitting rapping shafts.
Collecting Rapping System:
Collecting rapping system consists of drive, series of shafts, plain bearing, etc. Normally it is
driven from the ESP side.
Emitting rapping system:
Emitting rapping system consists of drive, vertical shaft, major and minor pin wheels, rapping
shaft, plain bearing, etc. (for top-driven design) or of drive, series of shafts, plain bearing, etc.
(for side-drive design). Rapping devices are important parts of ESPs. By rapping at regular
intervals, dust accumulated on both collecting plates and emitting electrodes is dislodged and
falls into hoppers. Both collecting and emitting rapping systems use tumbling hammers to
carry out side rapping. Since the plain bearings are attached to the elements of emitting
system at negative high voltage, to isolate the high voltage, a porcelain shaft insulator is
inserted serially between two runs of the same emitting rapping shafts.
Earthing:
The ESP is operating under high voltage and normally with negative corona, which means its
casing and collecting system have the same potential. To protect high voltage equipment and
ensure personal safety, the ESP must be earthed reliably with requirements as follows:

a. Resistance of the earthed grid should be less than 2 ohms all the year round

Prepared by (PMPL): Reviewed by (PMPL): Reviewed by (PPGCL): Approved by (PPGCL):

Signature: Signature: Signature: Signature:

Name: Name: Name: Name:

Desg.: Operation In-Charge Desg.: Site In-Charge Desg.: Operation In-charge Desg.: Plant Head
 STANDARD OPERATING PROCEDURE
PPGCL Super Thermal Power Plant
3 X 660 MW.
FIELD SOP FOR ESP LINE CHARGING.
Document No.: Revision No.: 01
Effective Date: Page 4 OF 8
PMPL/AHP/SOP/11 Revision Date:

b. The arrangement of the earthed grid should be such that the surroundings have
even voltage to ground.

4. Operating Procedure: Charging and Discharging Of Electrostatic Precipitator:

Charging of Electrostatic Precipitator:

1. Check and ensure that the equipment maintenance work completed and
NO PTW pending.
2. Also check for Manholes and Inspection holes have been closed properly.
3. Check that to see that the motors for rapping, ash discharge, etc. have the
correct direction of revolution, that they can turn freely,
4. Remove all foreign materials left within the electric fields.
5. Rapping devices are in good condition without damaged and oil level is
normal in transformer oil gauges.
6. Check that High-voltage switch cabinet and rectifier transformers are in
good condition and no oil leakage observed. The grounding wire of
device outer is properly connected.
7. Check that High-Voltage cabinet disconnected switch has been connected
back. Wire and cables of rectifier transformers are well connected. All
Manholes and high-voltage switch cabinet have been closed and locked.
8. Insulation resistance using high-voltage insulation components by 2500V
Mega ohm meter should be 500 M ohm.
a) Earth resistance of electrostatic precipitator should be below 2 ohm.
b) Insulation resistance of rapping motor, air door motor, and dust discharging
motor and their cables by 500V Mega ohm meter should be below 0.5 ohm &
collecting &emitting rapping motor
9. All ash hopper heaters and Collecting & Emitting Rapping motor should
be in service for at least 8 hours before putting the ESPs in service.
a) Put all hopper heaters on the control panel to ‘’AUTO’’ Mode.
b) All the heaters have been turned on for at least 8 hours before the
start-up of ESP, so as to ensure that inside of all hoppers and various
insulators (support insulators, shaft insulators, etc) are dry, and to
avoid any damage caused by electric creep age due to condensation.
Check all electric heaters to see if the current is correct
c) Check the alarm functions on the test control panels to see if the
tripping functions are normal
d) Start ‘’Hopper Fluidizing Blower’’ from control panel and after 30-
40 seconds start fluidizing heater from control panel. Maintain 15kpa
blower discharge pressure.
e) Remove the ground components of high-voltage parts and open
circuit between Emitting and collecting rapping.

f) Start the I.D. fan

g) Lead flue gas into the ESP to eliminate the moisture on various
internals. This period of warm-up depends on the temperature and

Prepared by (PMPL): Reviewed by (PMPL): Reviewed by (PPGCL): Approved by (PPGCL):

Signature: Signature: Signature: Signature:

Name: Name: Name: Name:

Desg.: Operation In-Charge Desg.: Site In-Charge Desg.: Operation In-charge Desg.: Plant Head
 STANDARD OPERATING PROCEDURE
PPGCL Super Thermal Power Plant
3 X 660 MW.
FIELD SOP FOR ESP LINE CHARGING.
Document No.: Revision No.: 01
Effective Date: Page 5 OF 8
PMPL/AHP/SOP/11 Revision Date:

humidity within each field and is usually ended when the temperature
at the outlet of the last field reaches a level higher than the gas dew
point. When oil is burning in the boiler never put the high voltage
T/R into operation.
h) Start the ash discharge system.
i) Ensure all the rapping devices.
j) Turn on all the functions of the rapping system. Set alarms, inter
locking, temperature detector and controller, ash level indicator, ash
discharger, etc. all in a mode of controllable operation.
k) When the fuel has changed from oil to coal and when the temperature
in the ESP is higher than the gas dew point, the ESP can be put into
operation, but must be running under a condition that the spark ratio
is zero.
l) All ESPs must be in service only after these conditions fulfill.
m) The Boiler load is more than 45% BMCR,
n) The exhaust Gas temperature of boiler is more than 120ᵒC.
o) Any of oil guns should not be in service.
p) Set the Automatic Voltage Controller to the ‘’Remote’’ position and
select the operation mode of electric field to ‘’Pulse’’ energy saving
mode.

Discharging of Electrostatic Precipitators:

10. When the ‘’RESET’’ button on the high-voltage cabinet panel is

pressed, the output of current and voltage will decline to zero. (On PC-
MTU).
11. Press ‘’STOP’’ button and disconnect the main circuit.
12. Change Emitting and collecting rapping to continuous operation mode for
not less than 10 hours.
13. Stop the ash hopper heating after after confirming the ash hopper is
cleared completely.
14. In proper sequence open the circuit breaker on the control cabinet of Ash
Hopper Heaters.
15. Keep Ash Hopper Heaters, Insulator Heaters and the Cathode ceramic
shaft heaters in service when Boiler is in shut-down for short period of
time and made ‘’OFF’’ if required.
16. Stop heaters and fluidizing blowers in a proper sequence.
17. Stop Electrostatic Precipitator immediately after the Boiler tripping.
5. POINTS TO BE CHECKED BY OPERATOR IN EVERY SHIFT
 EQUIPMENT CLEANING
 PHYSICALLY VIBRATION CHECKING
 PHYSICALLY TEMPRATURE CHECKING

Prepared by (PMPL): Reviewed by (PMPL): Reviewed by (PPGCL): Approved by (PPGCL):

Signature: Signature: Signature: Signature:

Name: Name: Name: Name:

Desg.: Operation In-Charge Desg.: Site In-Charge Desg.: Operation In-charge Desg.: Plant Head
 STANDARD OPERATING PROCEDURE
PPGCL Super Thermal Power Plant
3 X 660 MW.
FIELD SOP FOR ESP LINE CHARGING.
Document No.: Revision No.: 01
Effective Date: Page 6 OF 8
PMPL/AHP/SOP/11 Revision Date:

 OIL LEVEL AND GREASE CHECKING

6. CHECKING OF SYSTEM AFTER SHUT DOWN
 PHYSICALLY CHECK BOTTOM ASH HOPPER AFTER OPENING THE MAN
HOLE DOOR AS LIKE FOREIGN MATERIAL AFTER THAT CHECK THE
ROTATION OF CLINKER GRINDER IN FORWARD AND REVERSE DIRECTION.
 CHECK THE OIL LEVEL FREENESS.
 PHYSICALLY ALL VALVE CHECKING MANUALLY OPERATION THROUGH
PLC AS WELL.
 FIRST ENSURE SLURRY AND ASH WATER SUMP CLEANING AND THEN FILL
THE SUMP.
 CHECK THE SEAL PRESSURE OF ALL DOME VALVE PHYSICALLY.
 CHECK THE LINE VACUUM AND SHUT OFF VACUUM OF ALL PASSES.
 CHECK FLUIDIZING BLOWER AIR OF INDIVIDUAL HOPPER.
 CHECK THE PURZING OF BUFFER HOPPER AND SILO BAG FILTER.
 IF ANY PROBLEM OBSERVED IN EQUIPMENT THEN INFORM TO SHIFT IN
CHARGE/ OPERATION IN CHARGE IMMEDIATLY.

Prepared by (PMPL): Reviewed by (PMPL): Reviewed by (PPGCL): Approved by (PPGCL):

Signature: Signature: Signature: Signature:

Name: Name: Name: Name:

Desg.: Operation In-Charge Desg.: Site In-Charge Desg.: Operation In-charge Desg.: Plant Head