PD 142 VM 03 004 - Rev 06 - ESP DBR

OC No.
Total sheets
DDC142
Document No. PD 142 VM 03 004 17 + (9 CRS)
ESP DBR DESCRIPTION
Revised as per
6 08.04.20 Info ARG/
comments SAS AR
RDS
Revised as per
5 28.12.18 Info
comments AT AB - - -
Revised as per
4 25.10.18 Info
Revised as per
3 30.08.18 Info
2 14.08.18 Revised Info
1 28.06.18 Revised Info
A 09.05.18 First Issue Info ARG/

- - - - AS AB - - -
HV
Mech
Appd
Appd
Civil
C&I
Elec
Ckd
Ppd
Ppd
PM
QA
Description of
Rev Date Status
Revisions
DEC THERMAX LTD.
GACL- NALCO ALKALIES & CHEMICAL PVT. LTD.,
OWNER
DAHEJ, GUJARAT
OWNER’S
STEAG ENERGY SERVICES (INDIA) PVT. LTD.,
ENGINEER NOIDA, INDIA
(PREVIOUS OWNER’S ENGR – DESEIN CONSULTING ENGINEERS, NEW DELHI)
BTG PACKAGE FOR
PROJECT 2 x 65 MW COGENERATION CAPTIVE POWER PLANT,
DAHEJ, GUJARAT
POWER DIVISION
THERMAX LIMITED
PUNE
Project: 2 x 65 MW CCPP (BTG), Document Title Doc. No. Rev. Sheet
GNAL, Dahej, Gujarat
Owner: GACL- NALCO ALKALIES
& CHEMICAL PVT. LTD., ESP DBR DESCRIPTION
Owner’s Engineer: STEAG PD 142 VM 03 004 6 2
ENERGY SERVICES (INDIA) PVT.
LTD.,
The 2 x 65 MW Cogeneration Captive Power Plant is being set up by GACL-NALCO

ALKALIES&CHEMICAL PVT. LTD., located at Dahej Gujarat, India.
The steam generator of this unit is being provided with ESP's to control the particulate emission.
These ESPs are guaranteed for particulate emission of 20mg/Nm3 with all fields in operation at
guarantee point.
MAIN FEATURES OF ELECTROSTATIC PRECIPITATORS

Electrostatic precipitation is a physical process by which particles suspended in gas stream are charged electrically,
and under the influence of electric field are separated from the gas stream. The precipitation system consists of a
positively charged collecting surface and a high voltage discharge electrode wire suspended from an insulator at the
top and held in position by a weight at the bottom. At a very high DC voltage of the order of 50 kV, a corona
discharge occurs close to the negative electrode, setting up an electric field between the emitter and the charged
surface. The particle-laden gas enters near the bottom and flows upward. The gas close to the negative electrode
is, thus, ionized upon passing through the corona. As the negative ions and electrons
migrate towards the charged surface, they in turn charge the passing particles. The electrostatic field then draws
the particles to the collector surface where they are deposited. Periodically, the collected particles are removed from
the collecting surface by rapping or vibrating the collector to dislodge the particles. The dislodged particles drop
below the electrical treatment zone and are collected for ultimate disposal. Usually, a larger number of these
collectors are placed in parallel
in a single housing, forming a multiple cylindrical unit. For industrial applications, vertical plates exposed to
horizontal gas flow (parallel -plate precipitators) are normally used. In this type of collector, the flue gas flows through
vertical parallel plates between which are suspended a number of vertical wires held in place by weights attached at
the bottom. These wires form the
Discharge electrode, while the vertical plates form the collection electrode. Figure 1 shows the schematic diagram of
a typical parallel plate arrangement. Although the multiple unit is not as widely used as the parallel plate
precipitator described below, it finds frequent use in collecting liquid particles.
.
A unique feature of electrostatic precipitators is the separating force that is applied directly to the
particles without the necessity of accelerating the gas as is done for all other particulate collection devices. This
unique feature leads to an extremely low pressure loss for the collection of fine particles compared with that in
any other type of collector.
The main features/advantages of ESPs are:
• can collect all types of dust, gas mist, droplets, etc.;
• can collect dust in both wet and dry conditions;
• can collect all sizes of particles, from microns to coursers;
• probably the most versatile collecting equipment;
• offers the highest efficiency, can be designed in principle for any efficiency without excessive
pressure drop;
• operates with low operation cost (though initial cost is more);
• can operate over a wide range of inlet conditions, i.e., temperature, pressure, dust burden, humidity, etc.;
• offers negligible pressure drop (rarely crosses 20–15 mm);
• can be built in multiple units, for almost any gas volume;
• It has a long life, comparatively free from abrasion effect due to low operating velocity;
• Current drain is virtually negligible, usually between 0.05–1.5 amp occasionally, the pressure drop available
from the flue itself is sufficient to dispense with added air moving equipment. This combination of reduced
pressure drop requirement and low current
Drain yields a system extremely economical both in size of blower/fan equipment and in power
LTD.,
consumption men. Maintenance is low, as there is no moving part; and

• The high recovery value of the dust collected offset s the cost of the equipment. In steel making, for
example, dust can be collected and added to the sinter mixer pelletized in a flying saucer and returned
directly to the steel making vessel without treatment.
The most economical design and operation of dry electrostatic precipitators is obtained when the resistivity of
particles fall within certain desired limits. If the resistivity is low, particles give up their charge too easily and become
re -entrained in the gas flowing past the collecting electrode. On the other hand, high resistivity particles cannot
lose their charge upon reaching the collector
Electrode because of the low conductivity of the material deposited earlier. As a result, the effective field strength is
reduced and the efficiency falls. Particle resistivity can be controlled in many cases by selecting the proper
operating temperature or by injecting water to reduce the resistivity. Such irrigated precipitators are used for the
collection of fumes from electric arc furnaces.
PRECIPITATOR COMPONENTS
All electrostatic precipitators, regardless of their particular designs, contain the following essential
components:
• Discharge electrodes
• Collection electrodes
• High voltage electrical systems
• Rappers
• Hoppers
Discharge electrodes are either small-diameter metal wires that hang vertically (in the electrostatic precipitator), a
number of wires attached together in rigid frames, or a rigid electrode made from a single piece of fabricated metal.
Discharge electrodes create a strong electrical
Field that ionizes flue gas and this ionization charges particles in the gas.
Collecting electrodes collect charged particles. Collection electrodes are either flat plates or tubes with a
charge opposite that of the discharge electrodes.
High voltage equipment provides the electric field between the discharge and collection electrodes used to
charge particles in the ESP.
Rappers impart a vibration, or shock, to the electrodes, removing the collected dust. Rappers remove dust that has
accumulated on both collection electrodes and discharge electrodes. Occasionally, water sprays are used to remove
dust from collection electrodes.
Hoppers are located at the bottom of the precipitator. Hoppers are used to collect and temporarily store the dust
removed during the rapping process.
The shell provides the base to support the ESP components and to enclose the unit.
Electrical hoist for lifting of TR set. - R02
It is MIGI ESP (magnetic impulse gravity impulse) no motor drives are required to operate rappers, External operating
platform shall be on one side of ESP( side of access door only) - R04
LTD.,
Interconnecting platform of 6 m (front) from Boiler to ESP (Drawing No-PD 142 VM 02 L01) - R01
Insulators are inside penthouse hence there is no need to any extra platform. One can comfortably do maintenance inside
penthouse.
Cladding type- Plain aluminium 22SWG, Insulation- Thk 50mm & density- 100Kg/m3
We are providing PLC based MTP panel for controlling rapping of electrodes.
Air leakage though ESP is <1%
COLLECTION SURFACE:
Collection surface is the surface provided per electrode for the given gas volume
Collection surface are made up of sheet metal generally having thickness ranging from 1.2 to 1.5 mm & serves to
allow the dust particle precipitation on to the plate for the particulate that is negatively ionized.
Collection surface plate is fixed / welded to casing of ESP and it is grounded.
There has been steady increase in the ESP size from the last decade to bring down the required outlet emission
and collection surface has utilized this trends.
Collection surface also involves other parameter like plate spacing, migration velocity and treatment time which are
defined by the required collection efficiency. Based on the required Collection efficiency against the projected gas
flow the relation of collection area is formulated.
It means the specific Collection surface area plays a vital role in sizing the ESP by taking care of the Process
parameter with respect to process Dust particle size and resistivity of the particle. The norms have been
standardized with respect to ESP Efficiency and the minimum collection surface area to be maintained.
Collection surface area are to be selected by keeping the required surface for amount of dust to be loaded for the
required velocity during rapping and periodically to maintain the electrical force between the electrode.
GAS VELOCITY:
Gas velocity is the velocity of the gas passing across the cross sectional area of a given precipitator and is calculated
3 2
by dividing the volumetric flow rate (m /Hr) of gas through the ESP by effective cross sectional area (m ) of the
precipitator
The main factor controlling the gas velocity is the Resistivity of the dust. If the resistivity of Dust is high there is a
chance of particle re-entrainment.
GD screen plays important role in maintaining the designed velocity throughout the cross sectional area of ESP.
Gas velocity parameter has become more generic in the collection efficiency. Modern ESP’s design typically has
gas velocity in the range of .6 to 1.2 m/sec with 300 to 400 mm spacing and is within good velocity range.
Gas velocity is 0.78 m/s for both ESP - R01
SPECIFIC COLLECTION AREA

The specific collection area (SCA) is defined as the ratio of collection surface area to the gas flow rate into the
collector. This ratio represents the A/Q relationship in the Deutsch- Anderson equation and consequently is an
important determinant of collection efficiency.
The SCA is given in below
ASPECT RATIO:
LTD.,
The aspect ratio, which relates the length of an ESP to its height, is an important factor in reducing rapping
loss (dust re-entrainment).When particles are rapped from the electrodes, the gas flow carries the collected
dust forward through the ESP until the dust reaches the hopper. Although the amount of time it takes for
rapped particles to settle in the hoppers is short (a matter of seconds), a large amount of "collected dust" can
be re-entrained in the gas flow and carried out of the ESP if the total effective length of the plates in the ESP is
small compared to their effective height. For example, the time required for dust to fall from the top of a 9.1-m
plate (30-ft plate) is several seconds. Effective plate lengths must be at least
10.7 to 12.2 m (35 to 40 ft) to prevent a large amount of "collected dust" from being carried
out of the ESP before reaching the hopper.
Aspect Ratio for Both ESP is 2.05- R01
TREATMENT TIME:
Treatment time is the time taken by a gas particle to travel the total collecting plate length in an ESP. The
treatment time for a given precipitator is calculated by obtaining the dividing Field Length by gas velocity.
This is defined as the time taken by the flue gas passing through the length of the collecting electrode zone.
In different application the treatment time is different depending upon their gas quality for boiler ESP, recovery
boiler, and biomass cement.
The more the treatment time is better collection efficiency are achieved and outlet emission are reduced.
The treatment time varies with respect to collection efficiency.
MIGRATION VELOCITY:
It is been said that, as the particle along with gas flow moves through precipitator, each charged particle has
a component of velocity moves toward the collecting plate. These components of velocity are called
migration velocity.
It has a great impact with process parameter depending upon the particle size, resistivity and gas flow
distribution inside the precipitator.
Migration velocity gets affected with re-entrainment of gas particle while rapping because of gas flow
distribution and gas leakage through the precipitator result in air volume disturbing the flow pattern of gas
flow uniformity.
Proper plate spacing is to be maintained electrical voltage stability for developing electric corona in
substantial form and to maintain the charge of particle and same is to be directed towards the collecting
plate.
Increased migration velocity achieves higher particle collection efficiency with less collection area.
Migration velocity is 4.25 CM/SEC for our ESP-R02

LTD.,
RAPPERS:-
Rappers are used for dislodgement of accumulated dust from the collecting electrode. Rappers play vital role in
maintaining the electrical voltage stability.
The deposited dust is dislodged by mechanical impulse or vibration of the electrodes, a process generally known
as rapping.
We are providing magnetic impulse gravity impulse rappers.
In magnetic impulse rapping, a pulse is generated from the controller to rapper coil and plunger is raised in a coil
and then drop back by gravity.
It is necessary to rap the discharge electrode to prevent dust buildup of excessive ash deposits which interfere
with the corona and thereby reduces the collecting efficiency.
These are the devices, generally located at the top of the ESP or bottom of the collecting plates, which periodically
impart shock to the collecting surfaces to dislodge the collected material into the hopper system.
GAS FLOW DISTRIBUTION:

In order to maximize the collection efficiency gas flow distribution plays a vital role.
Gas flow distribution pattern throughout the cross section of the ESP should be uniform.
Gas distribution test (GD Test) is done in clean ESP just before commissioning usually at 100% flow at ambient
temp to ensure the uniformity of the flow in every passage.
Reading of GD test are taken at the outlet of the field along the gas flow direction at 1 mts interval in every passage
of collecting electrode height from bottom to Top.
It has also to be checked the flow inside the Hopper zone below the field and above the baffle. In the hopper zone the
velocity should be zero. It is to ensure any leakages from the hopper zone.
LTD.,
Material Thickness- R01
Item Plate work Plate work Stiffener/Support

OWNER HARDUAGANJ HERMA
Thickness Material Material
UPRVUNL STATION, EXTENSION-I
Casing walls 5.0mm IS 2062 or Eq. IS 2062 or Eq.
Interior 5.0mm IS 2062 or Eq. IS 2062 or Eq.
girders/Columns
Hoppers 6.0mm IS 2062 or Eq. IS 2062 or Eq.
Hopper baffles. 3.15 mm IS 1079 or Eq. IS 2062 or Eq.
Hopper liner 1.6 mm SS304 NA
Casing roof 5.0mm IS 2062 or Eq. IS 2062 or Eq.
GD Screen 2.5 mm IS 1079 or Eq. IS 2062 or Eq.
Inlet & outlet Cone 5.0mm IS 2062 or Eq. IS 2062 or Eq.
Perforated plates 2.5mm IS 1079 or Eq.
Collecting 1.2 mm CRCA sheet IS 513, Gr.D
electrodes
CE Support Frame IS 2062 or Eq.
Discharge IS 513, Gr.D ·
Electrodes
DE pipe frame & support IS 1161, IS 2062 or Eq.
Support insulators Porcelain
ESP Structural design basis
A] FOR ESP (CASING,HOPPER)

ESP casing is housing mainly the collecting electrodes, and emitting electrodes
along with its supporting members, is designed to take care of
1. Dead load
2. Live load
3. Normal and exceptional pressure = ± 660 mm of WC at 67% of yield
strength and a temperature of 200°C.
4. Design temperature = 200°C and Short temp excursion temperature =
300°C for 30 mins (Max) for ESP Casing, its elements and hopper etc.
5. Wind forces.
6. Earth quake forces.
All these loads are transferred to the ESP supporting structure, through slide support
bearings & fixed foot.
Dead load and Live loads are transferred as axial load to all columns. Wind/seismic
loads are transferred as horizontal forces transferred to the base through diagonal
bracing provided.
LTD.,
Space provision for dummy has been shown in GA drawing. - R01
B] FOR ESP SUPPORTING STRUCTURE

1.1 OFFICIAL RULES & TEXT FOR ESP SUPPORT STRUCTURE
CALCULATION:
The following official rules and texts shall be applied.
1.2 Code of practice for use of structure steel in general building construction: IS:
800-2007 and design shall be done as per working stress method.
1.3 Code of practice for use of structural safety of buildings-Loading standards:
18:875-1987
1.4 Criteria for earthquake resistant design of structure: 18:1893-(Pat 1 & 4)
LTD.,
2.1 LOADS & OVER LOADS TAKEN INTO ACCOUNT FOR CALCULATION:
Steel structures are designed on the basis of permanent loads, .imposed loads, and
action due to wind/seismic forces and temperature load.
The most unfavorable combinations of the above mentioned forces have to be

considered as required by IS: 875-1987.
2.2 DEAD LOADS:

Dead loads are considered due to self-weight of equipment mainly consisting of casing
components, collecting electrodes, emitting electrodes, inl t. outlet nozzles,
penthouse, hopper, etc. as defined by T h e r m a x documents and other applicable
loads which will have implication on supporting structures.
2.2.1Additional loads due to Employer Facilities as per technical Specification.

a) Cantilever loads of not less than 2000 kg/mat a distance of 1200 mm from the
external face of the columns on either side, for cable trays and walkways.
b) Dry Fly Ash Piping Loads (Considering 800 kg/hopper).
2.3 LIVE LOADS:
Live loads are considered mainly due to
2.3.1 Ash stored up to the top of the hopper level
Additional ash build-up from the end of the third field up to the inlet duct bottom level at
a natural repose angle not less than 30 o -to horizontal in any case as per Tech. Spec.
c1:8.01.00 of section-1, Annexure -1, Volume II, For dust profile refer sketch at 2.5
2.3.2 Live load on platform, considered as 500 kg/sq.m.
Ash bulk density considered for structural design- 1350 kg/cu.m. As per Tech. Spec. - R02
2.4 WIND LOADS:
2.4.1 Basic wind speed at project site is 47 m/sec. as per IS: 875 -1987 Part-3
Probability factor,(k1 risk coefficient), terrain, height and structure size factor,
k2 and topography factor, k3 shall be as per IS:875.
k1= 1.07, k2 = 0.87 (Cat.4, Class C), k3=1
LTD.,
2.5 SEISMIC LOADS:
Seismic analysis shall be carried out as per the latest edition of IS: 1893 (Part 1
& 4). Zone-III shall be considered for design.
 The structures shall be classified into four categories as per table 5 of
IS: 1893 (Part4), this structure is considered under Category 2.
 Importance factor for each structure shall be as per Table 2 of IS:1893
(Part4). I = 1.75
 Method of analysis for each structure shall be decided as per clause 10.3
IS: 1893 (Part4), which depends on the seismic zone & category of the structure.
 Response Reduction factor shall be as per Table 3 of IS: 1893 (Part4). R= considered.
2.6 Calculation for Ash loads in hopper for dead load calculation Case
I: Hopper Ash Load Calculation:
Density of Dust= (p) = 1350 kg/m3

Volume of one Hopper = 66.2 m3R02 Total
no. of hopper/pass= 12
Total volume of dust in the Hopper= 794.4m³
Total Hopper Dust Load = 1072 .44 T
(Additional ash between hopper and collecting plate bottom- for fields 1 to 6)
Approx. = 70 T I ESP
LTD.,
2.7 TR SET SIZING

1) Field, Chamber per ESP 6Fields
2) Collecting Area per Field per

Chamber
= 3787.5m 2
3) Spacing(CE-DE) 20cm- R02
4) Operation Mode IE Mode (Semi Pulse Mode)
5) Insulation Voltage 4 kV/cm- R02
6) Calculated Voltage Ra ting 4 kVx20 cm

=80 Kv- R02
7) Selected Voltage Rating 111 kV- Since we are giving higher rating as
per out TL std for sizing-R02
8) Current Density
' 0.29mA/mL (experiential value of Thermax
For similar application.)
9) Calculated Current for ·field 3787.5mL x 0.29mA/mL
= 1098.37 mA
10) Selected Current Rating 1100 mA
11) Corona Power per unit (111 kV X 1100 mA)/3787.5m- - R02

effective Collection area = 32.24 W/m 2
LTD.,
Clause Part Description Value Unit Description Value Unit

2.8 Hopper Sizing Calculation for New ESP-
(Nm3 3
0.0 Gas flow rate per pass (Q) 460800 Inlet dust load 38 gm/ Nm
/Hr)
Minimum Dust Hopper

0.1 Gas temperature at ESP inlet 145 Degree Storage 8 Hrs
Time
Minimum hopper valley angle

0.2
(Std.)
60 Degree R-02
0.3 Collected Ash Quantity (We) 11431 Kg/Hr
This is effect of ESP
Applied ash collection efficiency collection Efficiency as
0.4 72 %
at 1st field hoppers well as dust falling due
to gravity.
0.5 Qty. in 1st Field of 8217
0.5 Qty in 2nd field 2313
Collected Ash in 1st Field/Hopper 8 hrs storage 2

0.6 32868 Kg
in given Storage time (Wh) hopper/Field
Density of Ash for volumetric

0.7 650 kg/m3
calculation (p)
0.8 Volume of Collected Ash, Vh 50.57 m3
Adding Volumetric margin

0.9 10 %
0.9(as per TS)
1.0 Required hopper volume required 55.62 m3
2.9 Hopper Valley Angle Calculation as

per Given data-R02
1.1 Hopper top side (A) 4.55 m
1.2 Hopper top side (B) 6.4 m
1.3 Hopper bottom side (C ) 0.35 m
1.4 Hopper bottom side (D) 0.35 m

1.5 Hopper height approx (H) 6.38 m
1.6 Total Designed Hopper Volume 66.20 m3
Designed Hopper Valley

1.7 60 degree
Angle
LTD.,
Since the hopper volume actual (66.20m³) is greater than the volume required as per
specification (55.62 m³) the sizing of hopper is OK. Further the requirement of hopper valley
angle 60° is also satisfied.
3.1.6 Colleting electrode rapping system

The collecting electrodes surface is kept clean by rapping them at the Top
intermittently. The rapping is done with the help of MIGI rappers.
The Discharge electrodes are kept clean by rapping the frame on which
these electrodes are mounted. The rapping is done with the help of MIGI
Rappers. These Rappers are mounted on a top that is running across the
gas-now in each field.
3.1.7 Insulator heating system

In order to prevent condensation and tracking of the insulators we are
providing band insulator heaters around the insulators (Support Insulator and
Shaft Insulator). This will prevent condensation of air around the insulator and
thereby leading to precipitation of the gases around the Insulators. We are
providing separate penthouse & purge air blower for housing of insulators.
3.1.8 Hopper level switch

Safety against dust deposition in hopper because of
improper dust discharge due to any reason we have experience that RF
capacitance type level switch which is most suitable for our ESP application
other than RF capacitance type level switch,
LTD.,
Hopper heater sizing
1. SIZING BASIS:
The hopper heating system shall be placed in each hopper for minimum lower one
third (1/3) of the bottom portion of dust hopper height. However, in any case this will not
be less than 1.5 m. The heating system shall be of low watt density {less than
3W/square inch of heated area), panel type to have uniform distribution of heat. The
Minimum heat input shall in no case be less than 500 watts/m 2 of hopper surface
area.
2. HEAT LOSS CALCULATION:-R02
Total surface area of hopper walls for the each hopper works out to 81.35 m2 and
1/3 Hopper Area= 11.02 m²
Elevation Side View

A-TOP WIDTH MM 1749 B-TOP WIDTH MM 2366
C-BOTTOM WIDTH MM 350 D-BOTTOM WIDTH MM 350
H-HEIGHT MM 2126 H-HEIGHT MM 2126
TOTAL SURFACE AREA-M² 11.02
Elevation Side View

LTD.,
A. Total Heat loss
Temperature Rise ∆T =Final Temperature (Hopper Surface) – Initial temperature

(Hopper surface)
= 140 deg – 50 deg = 90 degC (Temperature rise)
Heat Loss for entire Hopper = K * A*T I X

= 0.048 * 81.35 * 90 /0.05 = 7.03 KW
A= Area of entire Hopper (m2). = 81.35 m2

X= Thickness of the insulation in meter = (50 mm)
K-value (Thermal conductivity) =0.048
B. As per Specification total heater capacity shall be 1/3 rd hopper area (in
Sqm) X 0.5 Kw.
1/3 rd hopper area =A1 = 11.02 m²

Heater capacity= A1 x 0.5 = 11.02 * 0.5 = 5.5 KW
Hence, the heating capacity ( i.e. 5.5 KW) per hopper is selected for an Insulation
thickness of min 50 mm.
Insulation Thickness Calculation

Parameters Figures UOM Remarks/Assumption
Gas Design Temp 145 Deg Cel
Normal Value: 55-60
Deg Cel, Keep 60 Deg
Expected Skin Temp 60 Deg Cel Cel
Normal Value: 40-45
Deg Cel, Keep 45 Deg
Max Ambient Temp 40 Deg Cel Cel
Thermal Conductivity of
Mineral wool having avg
density of 100-200 Kcal/m hr
Kg/m3 0.048 Deg cel. Reference from IS :8183
Thermal Conductivity
conversion to mW/Cm2 mW/Cm2
Deg Cel 0.55824 Deg Cel Reference IS :3346
Surface Coefficient for Al mW/Cm2
Cladding 0.57 Deg Cel Reference IS :3346
Insulation Thickness in cm 4.162315789 cm
Insulation Thickness in mm 41.62316 mm
LTD.,
VALLEY ANGLE CALCULATION – R03
Valley Angle Calculation
B = 2990 mm
C = 2068 mm
A= √(B2 + C2)
√(29902 + 20682)
A= 3635 mm
TAN VA = H/A
Valley Angle = Tan-1 (6379/3635)
Valley Angle = 60 Deg.
NOTE – R04
1. Opacity Analyser & CEMS - Opacity analyzers are provided and already indicated in Boiler P&ID. For flue gas
duct emission monitoring CEMS is already provided in chimney in Boiler P&ID (PD 142 VM 01 005).
LTD.,
2. Level Switch - Each ESP hopper is provided with 3 nos. level switch (switches 2 nos. for high level and 1 no.
for low level). The same is indicated in ESP P&ID (PD 142 VM 03 001).
3. RTD - Each ESP Hopper will be provided with 2 nos. RTDs to control the temperature of ash through hopper
heater. The same is indicated in ESP P&ID (PD 142 VM 03 001).
4. 3D acoustic level transmitter - One set of 3 D type Acoustic wave type level transmitter for each ESP Hopper
(First field) measuring Level, Volume & Mass is provided. The same is indicated in ESP P&ID (PD 142 VM 03
001).
5. UPS System - UPS power will be available for powering OWS, Printers & panels. UPS power is being fed from
the central UPS with battery for BTG package located at STG building.
6. OWS for Bunker level & ESP 1st field Hopper level monitoring is provided as per the contract specification. -
(R05)
7. ESP shall be controlled and monitored from DDCMIS OWS from Central Control Room in STG building. Local
OWS as extension of DDCMIS is provided. -(R06)

PD 142 VM 03 004 - Rev 06 - ESP DBR

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PD 142 VM 03 004 - Rev 06 - ESP DBR

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OC No.

ESP DBR DESCRIPTION

2 14.08.18 Revised Info

1 28.06.18 Revised Info

A 09.05.18 First Issue Info ARG/

The 2 x 65 MW Cogeneration Captive Power Plant is being set up by GACL-NALCO

MAIN FEATURES OF ELECTROSTATIC PRECIPITATORS

consumption men. Maintenance is low, as there is no moving part; and

Electrical hoist for lifting of TR set. - R02

Air leakage though ESP is <1%

Gas velocity is 0.78 m/s for both ESP - R01

SPECIFIC COLLECTION AREA

The SCA is given in below

Aspect Ratio for Both ESP is 2.05- R01

Migration velocity is 4.25 CM/SEC for our ESP-R02

We are providing magnetic impulse gravity impulse rappers.

GAS FLOW DISTRIBUTION:

Material Thickness- R01

Item Plate work Plate work Stiffener/Support

ESP Structural design basis

A] FOR ESP (CASING,HOPPER)

Space provision for dummy has been shown in GA drawing. - R01

B] FOR ESP SUPPORTING STRUCTURE

The following official rules and texts shall be applied.

The most unfavorable combinations of the above mentioned forces have to be

2.2 DEAD LOADS:

2.2.1Additional loads due to Employer Facilities as per technical Specification.

2.3 LIVE LOADS:

Live loads are considered mainly due to

2.3.1 Ash stored up to the top of the hopper level

2.4 WIND LOADS:

2.5 SEISMIC LOADS:

I: Hopper Ash Load Calculation:

Density of Dust= (p) = 1350 kg/m3

2.7 TR SET SIZING

2) Collecting Area per Field per

3) Spacing(CE-DE) 20cm- R02

4) Operation Mode IE Mode (Semi Pulse Mode)

5) Insulation Voltage 4 kV/cm- R02

6) Calculated Voltage Ra ting 4 kVx20 cm

10) Selected Current Rating 1100 mA

11) Corona Power per unit (111 kV X 1100 mA)/3787.5m- - R02

Clause Part Description Value Unit Description Value Unit

Minimum Dust Hopper

Minimum hopper valley angle

Collected Ash in 1st Field/Hopper 8 hrs storage 2

Density of Ash for volumetric

Adding Volumetric margin

1.0 Required hopper volume required 55.62 m3

2.9 Hopper Valley Angle Calculation as

1.1 Hopper top side (A) 4.55 m

1.2 Hopper top side (B) 6.4 m

1.3 Hopper bottom side (C ) 0.35 m

1.4 Hopper bottom side (D) 0.35 m

Designed Hopper Valley

3.1.6 Colleting electrode rapping system

3.1.7 Insulator heating system

3.1.8 Hopper level switch

Hopper heater sizing

2. HEAT LOSS CALCULATION:-R02

1/3 Hopper Area= 11.02 m²

Elevation Side View