Ref: AQCS:FARAKA:GDT:002

GAS DISTRIBUTION TEST PROCEDURE

Date of Issue : 22.02.14

PROJECT NTPC – FARAKKA STPP– STAGE-III : UNIT-6 (1X 500 MW)

National Thermal Power Corporation

ESP GAS DISTRIBUTION TEST PROCEDURE

FARAKKA STPP STAGE-III

UNITS-6
1 X 500 MW

PREPARED BY : J. Abinaya Radha

REVIEWED & APPROVED BY : G. Gunasekar
DATE OF ISSUE of Rev 00 : 20.08.07
ISSUED BY : AGM/AQCS
NO. OF PAGES INCLUDING THIS PAGE : 10
NTPC DOCUMENT NUMBER : 4140-108-05RN-PVM-W-070
BHEL DOCUMENT NUMBER : RP-DC-268-107-0813
REVISION / Date : 02 / 22.02.14

Rev No. Date: Details

01 26.10.10 Revised in line with the approved GD test procedure of NTPC-
Simhadri. Digitally signed
Signature Not
by BVerified
GANESH
02 22.02.14 Date:00
Clarification for comments received on Rev 2014.03.11
document is also
14:32:08 IST
Reason: CAT IV
included in Pg 10/10. Location:
NTPCEOC

BHEL NTPC
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 Ref: AQCS:FARAKA:GDT:002
GAS DISTRIBUTION TEST PROCEDURE
Date of Issue : 22.02.14

PROJECT NTPC – FARAKKA STPP– STAGE-III : UNIT-6 (1X 500 MW)

INDEX

1. PLANT DETAILS

2. OBJECTIVE

3. PROPOSAL

4. SERVICES REQUIRED

5. SAFETY PRECAUTIONS

6. EMERGENCY PROCEDURES

7. STATE OF THE PLANT

8. METHOD

9. COMPLETION CRITERIA

BHEL NTPC
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 Ref: AQCS:FARAKA:GDT:002
GAS DISTRIBUTION TEST PROCEDURE
Date of Issue : 22.02.14

PROJECT NTPC – FARAKKA STPP– STAGE-III : UNIT-6 (1X 500 MW)

1.0 PLANT DETAILS

1.1 One number of ESP with four passes is provided in each 500 MW Unit for
precipitating the dust emanating from the Boiler.

The ESP is made of steel casing and fitted with hoppers, inlet / outlet funnels,
1.2
internals such as collecting & emitting electrodes, their rapping mechanisms,
distribution screens, hopper heaters and support insulators. Rectifier Transformers on
the top of ESPs supply HVDC to electrodes.

1.3 Specifications of ESP :

 ESP Type : 4XFAA – 10 x 45H – 2 x 90135 – 2
 No. of ESPs per Boiler :1
 Design Gas flow : 818.4 m3 / sec
(total for 4 passes of the ESP)
 Flue gas temp at ESP inlet : 1250 C
 Duct velocity : 9.39 m / s
 Velocity inside ESP : 0.84 m / s

1.4 No. of test points

 No. of points across width per pass : 26
 No. of vertical points per pass : 12
 Total number of test points per pass : 312

1.5
Uniform gas distribution across the cross section of precipitator helps effective
utilization of the collection area provided in the precipitator and thus improves
collection efficiency.

BHEL NTPC
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GAS DISTRIBUTION TEST PROCEDURE
Date of Issue : 22.02.14

PROJECT NTPC – FARAKKA STPP– STAGE-III : UNIT-6 (1X 500 MW)

2.0 OBJECTIVE

2.1 To achieve and verify uniform flow distribution inside the ESP chambers.
2.2 To verify equal flow distribution among the ESP passes.

3.0 PROPOSAL

3.1 The Test shall be conducted in two parts.

3.2 PART 1 of the test shall be conducted before commissioning with cold air by
running both ID & FD Fans. The velocity readings shall be taken inside the
precipitator chambers.
3.3 Digital or analogue vane type Anemometer shall be used for measuring the velocity.
3.4 The test will be conducted for all the four passes of the ESP
3.5 Measurements shall be taken between 1st and 2nd fields of all passes of ESP. Apart
from this the measurements shall also be taken between last and last but one field of
one pass of the ESP.
3.6 PART 2 of the test shall be conducted at Full load. The velocity and Temperature
readings shall be taken at the inlet ducts of each pass of ESP.

3.7 The test results shall be compared with the norms formulated by Industrial Gas
Cleaning Institute (IGCI).

BHEL NTPC
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GAS DISTRIBUTION TEST PROCEDURE
Date of Issue : 22.02.14

PROJECT NTPC – FARAKKA STPP– STAGE-III : UNIT-6 (1X 500 MW)

4.0 SERVICES REQUIRED

4.1 Anemometer.
4.2 Inclined Micromanometer with S-Type Pitot Tube calibrated from a recognized
laboratory.
4.3 K-Type thermocouple with digital temperature indicator calibrated from a
recognized laboratory
4.4 Required lighting and communication facilities in test area.

5.0 SAFETY PRECAUTIONS

5.1 Ensure the availability of first aid kit near the test area.
5.2 Ensure the availability of safety helmets with the test team.
5.3 Ensure that the stair-cases, floor grills, hand rails are erected in ESP particularly at
and around approach area near the chamber inside which test is conducted.
5.4 Ensure that the agencies working near the test area are informed about the ongoing
test inside ESP.

6.0 EMERGENCY PROCEDURES

A good communication system should be established between the team conducting
6.1
the test inside ESP, the team coordinating from outside ESP and Unit control room
for starting, loading, stopping etc of ID and FD Fans etc.

BHEL NTPC
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GAS DISTRIBUTION TEST PROCEDURE
Date of Issue : 22.02.14

PROJECT NTPC – FARAKKA STPP– STAGE-III : UNIT-6 (1X 500 MW)

7.0 STATE OF THE PLANT

7.1 PART 1

7.1.1 The precipitator and the Boiler system are ready.

7.1.2 Erection of ESP internals and their alignment is complete.

7.1.3 ESP Air-in-leak test is complete and leakages into the ESP chamber through manhole
door, openings in hopper bottom and openings of insulator housings have been
attended.

7.1.4 Guide vanes are positioned as shown in the duct layout of Flow Model Test Report.

7.1.5 The primary and the secondary screens in the Gas Distribution housing are erected
and aligned.

7.1.6 The deflection plates are installed on the primary and secondary screens as per the
flow model test report.

7.1.7 ID Fans and FD Fans are ready for full load operation.

7.1.8 The dampers and gates in ESP inlet / outlet ducts are in operating condition.

7.1.9 The measurement points are distinctly marked on the trailing edge of the collecting
electrodes of the first and last but one fields. The vertical spacing between the points
is approximately one meter leaving a gap of 750 mm from the top and bottom of the
collecting electrode. The velocity reading shall be taken every alternate collecting
electrode. Total number of test points per pass shall be 312.

7.1.10 Only one man-hole door of ESP pass is kept in unlocked condition to facilitate entry
and exit of the members of the test team.

7.1.11 Entire ESP and flue gas inlet and outlet ducts connected to ESP pass are thoroughly
checked and all foreign materials found inside are removed.

BHEL NTPC
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GAS DISTRIBUTION TEST PROCEDURE
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PROJECT NTPC – FARAKKA STPP– STAGE-III : UNIT-6 (1X 500 MW)

7.2 PART 2

7.2.1 The Unit is running at full load at rated parameters.

7.2.2 All the four passes of ESP are simultaneously in service.

8.0 METHOD

8.1 PART 1

8.1.1 ID and FD Fans are started and loaded gradually to establish velocity inside the
precipitator nearer to design value.

8.1.2 Using anemometer velocities are measured at pre-determined locations.

8.1.3 The test is conducted on trial and error basis only and hence more than one trial may
be required in case the results do not meet the completion criteria.

8.1.4 Adjustments, if necessary, are carried out to modify the location of deflection plates
on the gas distribution screen till the completion criteria are met.

8.2 PART 2

8.2.1 Velocity head and Temperature readings are taken at identified number of points, as
described in the PG Test procedure of ESP, in each of the ESP pass inlet ducts using
S-type Pitot Tube with inclined micromanometer OR digital manometer & K-type
thermocouple with digital temperature indicator.

8.2.2 Average flow per ESP pass is calculated and the average is compared with the
individual ESP pass flow.

BHEL NTPC
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GAS DISTRIBUTION TEST PROCEDURE
Date of Issue : 22.02.14

PROJECT NTPC – FARAKKA STPP– STAGE-III : UNIT-6 (1X 500 MW)

8.3 SAMPLE CALCULATION

For each duct

For each of the measured velocity heads corresponding values of (V x √ γt ) is found

out from the standard tables used for ESP PG Test.

If average of these (V x √γt) is Vh , and

ta is the average temperature then

γt =[γt (Design) x (tDesign + 273)] / (ta + 273) ]

=[0.864 x (125 + 273)] / (ta + 273) kg /m3

From this value of γt average flue gas velocity in each duct is calculated.

Therefore,

V(average flue gas velocity) = Vh / √γt m/sec

Flow = [V(m/sec) x Duct area (m2)] m3/sec [Duct area = 9.86 m2 ]

If Fa1, Fa2, Fb1,……. are calculated flows in the 8 (Eight) Bus ducts then

Average flow per ESP pass= Favg = [Fa + Fb + Fc + Fd ] / 4

Where Fa = Fa1+Fa2 , Fb = Fb1 + Fb2 ,…….

The average flow is compared with the individual ESP pass flow and the deviation is
calculated.

e.g., deviation in bus pass A = [(Fa - Favg) / Favg] x 100 %

BHEL NTPC
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GAS DISTRIBUTION TEST PROCEDURE
Date of Issue : 22.02.14

PROJECT NTPC – FARAKKA STPP– STAGE-III : UNIT-6 (1X 500 MW)

9.0 COMPLETION CRITERIA

9.1 PART 1

9.1.1 Within the treatment zone, the velocity pattern shall have a minimum of 85% of the
velocity readings less than 1.15 times average velocity and 99% of the velocity
readings less than 1.4 times the average velocity.

9.2 PART 2

9.2.1 The variation in flow among the ESP passes shall be within + 10 % of the average
flow.

BHEL NTPC
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GAS DISTRIBUTION TEST PROCEDURE
Date of Issue : 22.02.14

PROJECT NTPC – FARAKKA STPP– STAGE-III : UNIT-6 (1X 500 MW)

S.No. NTPC Comment BHEL clarifications

1.0 Sl.No. 1.4 of the procedure We confirm that the number of points i.e. 312
(No. of test points for GD test): indicated is for one pass and not for all passes of
a) It is to be clarified whether ESP. There are four passes per boiler.
total no. of points (312 points) The arrangement of sampling points will be an array
pertains to a single pass or all of matrix of 26 columns and 12 rows. The measuring
passes of the ESP. section would be the cross section inside ESP at the
b) The sketch indicating trailing edge of the ESP first field. Column wise it
position of test points to be would be between the collecting electrodes (CE) at
submitted. alternate ducts (Here duct mean passage between
adjacent CEs). Row wise it would be at number of
elevations (at equidistance) from top to bottom of the
electrode system at each of the above alternate CE
ducts. The sketch shown below is a typical
arrangement of measurement columns i.e. when
vertical lines represent CEs then the grey columns
would represent ducts for sampling locations.
2.0 Sl. No. 7.1.4 :
a) Flow model test report Flow model test report with guide vane position was
indicating position of the guide already furnished to NTPC.
vanes in the FG duct to be
submitted.

BHEL NTPC
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