Station: JPL, Tamnar Page 2 of 12

BHEL/TSX/JPL/BLR-CP/01
Stage II: (4X600 MW)
Plant Area: Boiler
Commissioning Procedure for Air in Leak test of ESP

Jindal Power Limited

O.P.J.S.T.P.P, Tamnar, Raigarh
Commissioning Department

Project OPJSTPP (4X600 MW), Tamnar

Procedure Air in Leak Test of ESP
Purpose of Document For Execution/Information
Document No. JPL Reference No: Boiler/Comm./012

Rev No. 00 Prepared By Reviewed By Approved By Date

Name

Sign

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JPL BHEL
Station: JPL, Tamnar Page 3 of 12
BHEL/TSX/JPL/BLR-CP/01
Stage II: (4X600 MW)
Plant Area: Boiler
Commissioning Procedure for Air in Leak test of ESP

List of Contents

1.0 Plant Details

2.0 Objectives

3.0 Proposals

4.0 Services Required

5.0 Safety Precautions

6.0 Emergency Procedures

7.0 State of the Plant

8.0 Method

9.0 Completion Criteria

10.0 Appendices

a) Drawing

b) Plot between KFilter & PsFilter

c) Log Sheets

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JPL BHEL
Station: JPL, Tamnar Page 4 of 12
BHEL/TSX/JPL/BLR-CP/01
Stage II: (4X600 MW)
Plant Area: Boiler
Commissioning Procedure for Air in Leak test of ESP

1.0 PLANT DETAILS

ESP is provided for precipitating dust emanating from the

Boiler. ESP has four gas passes.

The ESP is made of steel casing. It is fitted with hoppers, inlet

/ outlet funnels and internals such as collecting and emitting
electrodes and their rapping mechanism. Electrical heaters
are provided for heating ash hoppers. Rectifier Transformers
housed at the top of ESP supply High Voltage DC to
electrodes.

Specifications of ESP

i Type of ESP : 4 x FAA – 10 x 37.5 M – 2x2x 112150 – 2

ii No. of ESP per Boiler : 04

iii No. of Gas Path per Boiler : 08

iv No. of Fields in series in each Gas Pass : 10

v Flue gas Temp. at ESP inlet : 139 0C

vi Design Gas Flow (Per pass) : 968.6 m3/sec

vii Suction pressure at ESP inlet : (-) 200 mmwc

viii Gas Velocity inside ESP : 0.73 m/s

ix Treatment Time : 49.6 sec

x Density of Gas : 0.865 kg/m3

xi Dust Concentration at ESP inlet : 70.3 g/Nm3

xii Guaranteed Collection Efficiency : 99.929 %

xiii Guaranteed Air-in-Leak into ESP : 1% of design gas flow

(9.68 m3/s)

2.0 OBJECTIVE

To prove that the air-in-leak into ESP is within the

guaranteed value of 1% of design gas flow rate.

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JPL BHEL
Station: JPL, Tamnar Page 5 of 12
BHEL/TSX/JPL/BLR-CP/01
Stage II: (4X600 MW)
Plant Area: Boiler
Commissioning Procedure for Air in Leak test of ESP

3.0 PROPOSAL

3.1 Air tightness test (conversely, ESP Air-in-leak Test) shall be

performed on each pass of precipitator on completion of
erection of ESP casing, hopper, inlet / outlet funnels with all
internals fitted as per the approved drawings. The test shall
be conducted at different pressure conditions viz., 100 mm,
150 mm, 200 mm, 250 mm and 300 mm of water column.

3.2 An external system comprising Fan, measuring elements and

temporary ducts will be used for conducting the Air-in-leak
Test of ESP.

3.3 Calibration certificate of Venturimeter from a recognized lab

will be submitted at the time of testing.

4.0 SERVICES REQUIRED

4.1 Availability of Fan & Measuring Elements

4.2 Availability of L.T. Power Supply

4.3 Availability of Lighting and Communication facility at test

area

4.4 Availability of manpower for checking leakages and test team

for conducting the test

5.0 SAFETY PRECAUTIONS

5.1 First Aid Box should be available near the test area.

5.2 Personnel deployed to conduct the test should be provided

with safety gadgets.

5.3 Temporary Scaffoldings should be erected in vulnerable areas

for ease in checking of leakages

5.4 Temporary systems viz., Power Supply Panel and Motor

should be properly earthed.

5.5 The area where test fan is located should be clearly marked to
avoid any accident / human injury.

5.6 Safety Rules Clearance Certificate should be in force.

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JPL BHEL
Station: JPL, Tamnar Page 6 of 12
BHEL/TSX/JPL/BLR-CP/01
Stage II: (4X600 MW)
Plant Area: Boiler
Commissioning Procedure for Air in Leak test of ESP

6.0 EMERGENCY PROCEDURES

6.1 The test team should be aware of the procedures to be

followed in case of accident involving injury to personnel.

6.2 A person should be posted near the fan and instructed to

switch off the fan in case any member of the test team directs
him to do so due to any emergency

6.3 The team conducting the test should be aware of the

operating procedure of fire extinguishers to be used for
quenching fire.

7.0 STATE OF THE PLANT

7.1 Erection of the concerned ESP pass is complete with casing,

hoppers, inlet & outlet funnels, ducts suitably dummied with
all internals filled in.

7.2 ESP is not insulated.

7.3 Hopper outlet opening is closed by suitable plates and Fly Ash
removal system is not connected to the hopper.

7.4 All manhole doors on the roof, inspection doors on the casing
and hoppers are closed.

7.5 Fan and motor arrangement is erected at a suitable location

near ESP and fan discharge connected to the flange of hopper
through a temporary duct via venturimeter (refer drawing
given in section 10.0)

7.6 A ‘U’ tube manometer with a least count of 1.0 mm is erected

as shown in the drawing

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JPL BHEL
Station: JPL, Tamnar Page 7 of 12
BHEL/TSX/JPL/BLR-CP/01
Stage II: (4X600 MW)
Plant Area: Boiler
Commissioning Procedure for Air in Leak test of ESP

8.0 METHOD

8.1 Start the fan keeping the control damper of the fan in
minimum position and allow the fan to reach its full speed.

8.2 Regulate the damper slowly and pressurize ESP such that
constant pressure differential is maintained in ‘U’ tube
manometer mounted on the hopper.

8.3 Find the volume of air being pumped in.

8.4 Repeat the test for different pressures in ESP viz., 100, 150,
200, 250 and 300 mmwc by suitably varying the damper
control of fan and note down corresponding pressure
differentials across the venturimeter

8.5 Using the above observations, the air leakage per pass is
calculated as per steps given below:

8.5.1 When stable conditions are established, the mass flow rate of
air through the fan, Venturimeter and the precipitator must
be constant.

8.5.2 The mass flow rate of air for the fan is

mf = Qxγ

where
Q = volumetric flow of air in m3 / hr
γ = density of air at test conditions in kg / m3

8.5.3 The mass flow rate through the Venturimeter can be written
as a function of the pressure differential and the co-efficient of
discharge of the Venturi.

mv = γ1 x Kventuri x Square Root (∆pventuri / γ1)

where

Kventuri = coefficient of discharge of Venturimeter

γ1 = density of air in Kg / m3

∆pventuri = pressure differential across venturimeter in

mmwc

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JPL BHEL
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BHEL/TSX/JPL/BLR-CP/01
Stage II: (4X600 MW)
Plant Area: Boiler
Commissioning Procedure for Air in Leak test of ESP

8.5.4 The mass leakage of air through ESP pass can be expressed
as

mfilter = γ2 x Kfilter x Square Root (Psfilter / γ2)

where

Kfilter = a constant to be determined

Psfilter = static pressure of air inside ESP

= pressure differential observed in “U” tube
Manometer

γ2 = density of air at conditions inside ESP

8.5.5 Since

mv = mfilter

γ1 x Kventuri x Square Root (∆pventuri / γ1) = γ2 x Kfilter x Square

Root (Psfilter / γ2)

For practical purpose

γ1 = γ2

Therefore

Kfilter = Kventuri x Square Root (∆pventuri / Psfilter) …………… (1)

8.5.6 And the leakage can be expressed as

Qleakage = Kfilter x Square Root (Psfilter / γfilter) ……........… (2)

where

γfilter = density of gas at operating conditions

Psfilter = actual static over pressure in ESP

8.5.7 The tests are conducted for different Psfilter conditions viz.,
100, 150, 200, 250 and 300 mmwc by suitably varying the
Fan control damper.

8.5.8 Kfilter is calculated from the known values of equation (1). A

plot is drawn between Kfilter and Psfilter. This plot will be a curve
as shown in the enclosed sketch. It may be inferred that Kfilter
is a constant

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JPL BHEL
Station: JPL, Tamnar Page 9 of 12
BHEL/TSX/JPL/BLR-CP/01
Stage II: (4X600 MW)
Plant Area: Boiler
Commissioning Procedure for Air in Leak test of ESP

8.5.9 Model calculation

Qleakage (m3/sec) = Kfilter x Square Root [Psfilter (kg/m2 OR

mmwc)/ γfilter (kg/m3)]

Assuming the following values for the purpose of calculation

Kfilter = 0.03

γfilter = 0.87

Psfilter = 200

Therefore

Qleakage = 0.03 x [√(200 / 0.87)]

= 0.455 m3/sec

This value of Qleakage is also cross checked from the

Venturimeter calibration curve for the corresponding value of
pressure drop across Venturimeter.

9.0 COMPLETION CRITERIA

The ESP Air-in-leak Test is declared to have been completed

satisfactorily if test results establish air leak 1% or less of
design gas flow rate.

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JPL BHEL
Station: JPL, Tamnar Page 10 of 12
BHEL/TSX/JPL/BLR-CP/01
Stage II: (4X600 MW)
Plant Area: Boiler
Commissioning Procedure for Air in Leak test of ESP

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JPL BHEL
Station: JPL, Tamnar Page 11 of 12
BHEL/TSX/JPL/BLR-CP/01
Stage II: (4X600 MW)
Plant Area: Boiler
Commissioning Procedure for Air in Leak test of ESP

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JPL BHEL
Station: JPL, Tamnar Page 12 of 12
BHEL/TSX/JPL/BLR-CP/01
Stage II: (4X600 MW)
Plant Area: Boiler
Commissioning Procedure for Air in Leak test of ESP

Sl. No. Time Venturimeter Static Pressure at ESP

LHS RHS Diff. Pr. LHS RHS Diff. Pr.

1.

2.

3.

4.

5.

6.

7.

8.

9.

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JPL BHEL