PROCEDURE FOR AIR IN LEAKAGE TEST OF ESP

PROJECT:M/s RAMAGUNDAM

UNIT 7 (500 MW)

BHARAT HEAVY ELECTRICALS LIMITED

(A Government of India Undertaking)
Power Sector Southern Region
474, Anna Salai, Nandanam, Chennai 600 035.

PROJECT

M/s. RAMAGUNDAM UNIT 7, 500 MW

PROCEDURE

AIR IN LEAKAGE TEST OF ESP

PURPOSE OF
DOCUMENT

FOR EXECUTION / INFORMATION

DOCUMENT NO.

PS:TSX:175:00:03

COPY NO:
ISSUED TO:

00
Rev. No.

KJ

MKS

KB

04.08.2003

Prepared by

Reviewed by

Approved by

Date

BHARAT HEAVY ELECTRICALS LIMITED

(A Government of India Undertaking)
Power Sector Southern Region
474, Anna Salai, Nandanam, Chennai 600 035.

Station: NTPC BHEL Ref No.PS-DC-202-500-0018

Ramagund NTPC Ref no COS-COMM- RGM/COMMG-PRO-010
am
Plant area: BOILER
AIR IN - LEAKAGE TEST OF ESP

LIST OF CONTENTS
1.0

PLANT DETAILS

2.0

OBJECTIVE

3.0

PROPOSAL

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

Sheet

AIR IN LEAKAGE TEST OF ESP

1.0

PLANT DETAILS

1.1

DESIGN PARAMETERS OF ESP at TMCR Design coal firing condition

(Guarantee point)

1.2

Flue gas flow rate

: 796 m3/s

Flue gas temperature at inlet in ESP

Inlet dust condition when firing Design

coal

: 60.0 g/Nm3

Guaranteed collection efficiency

99.958%

Density of the gas

0.862 kg/m3

Suction pressure at ESP inlet

200 mmWc

Guaranteed Air-in-leakage into ESP

7.96 m3 /S, (1% of

Guarantee point flow)

FAN

Type

HCMB 3 050

Flow

20000 m3 /hr.

Speed

2640 rpm

Pressure

7000 pascals

Power

46.5 KW

Density

1.2 Kg/ m3 at 20 Deg C

Type

TEFC foot mounted motor

Volts

440 volts 50 Hz 3 phase

Power

55 KW, 2 pole

1250C

2.0

OBJECTIVE:

2.1

To perform air tightness test on each of the precipitator on completion of erection

of ESP casing hopper inlet / outlet funnels with all the internals filled in.

3.0

PROPOSAL
The test shall be conducted for different pressure conditions viz 100 mm, 150 mm,
250 mm and 300 mm water column.

4.0

SERVICES REQUIRED

4.1

Owners fly ash removal system shall not be connected to the hopper.

4.2

Inlet and outlet duct connections shall be left open.

4.3

415 V, 3 phase, 50 Hz temporary electrical supply for conduct of the test shall be
provided.

4.4

A suitable venturimeter for measurement of air-in-leakage into ESP. The

Calibration certificate for the venturimeter will be furnished at the time of testing.

5.0

SAFETY PRECAUTIONS:

5.1

Required quantities of safety gears such as Helmets, Nose-Pads, safety Goggles

etc. should be available

5.2

First Aid Box should be available near ESP area.

5.3

Service water should be available near the activity area.

5.4

The ESP area should be barricaded.

6.0

EMERGENCY PROCEDURES:

6.1

The group involved in carrying out the activity should be aware of the procedures
to be followed in case of accidents involving insure to personnel.

6.2

The group should be aware of operating procedures of portable fire extinguishers

to be used for quenching minor fires.

6.3

The group should be aware that if any abnormality is observed in the system
during the activity, the air tightness test should be terminated and appropriate
action taken to address the emergency.

7.0

STATE OF THE PLANT

7.1

Inlet and outlet funnel openings are blanked off by suitable plates.

7.2

Hopper outlet openings are blanked off by suitable plates.

7.3

All man holes on the roof, inspection doors on the casings and the hoppers are in
closed condition.

8.0

METHOD

8.1

Mount the Fan motor arrangement in line with the Venturi-meter and connect it to
the flange of any one of hoppers so that pressurization of ESP internals can be
done through this arrangement. Also mount an U tube manometer on a tapping
provided on the hopper adjacent to the pressurization equipment as shown in
enclosed drawing no.4-00-111-29672.

8.2

Once all known openings are closed, pressurize the ESP by fan and motor
arrangement such that the constant pressure differential is maintained in U tube
manometer mounted on the hopper.
Observe the volume of sir being pumped in, for constant pressure difference by
the pressure drop across the Venturimeter.
Repeat the test for number of readings of different pressure and note down the
corresponding pressure differentials across the Venturimeter.

8.3

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

Qr

Volumetric flow of air in m3/hour

the density of air at test conditions in kg/m 3

Where

The mass flow rate through the venture can be written as function of the pressure
differential and co-efficient of discharge for the Venturi.
=

r1 x k vent x p vent
r1

where
k vent

Co-efficient of discharge for Venturi-meter

r1

The density of air in kg/m3

p vent

The pressure differential across Venturi in mmWc.

The mass leakage of air through Electrostatic Precipitator can be expressed as

m

filter

= r2

Psfilter
r2

Where,
K filter

A constant to be determined.

Ps filter

Static pressure of air inside Electrostatic Precipitator

(Pressure differential as observed in U tube
manometer).

r2

The density of air at Electrostatic Precipitator condition.

r1 x k vent

p vent
r1

= r2 x k filter x

Psfilter
r2

for practical purpose r1 can be taken as r2

Therefore, K filter

K vent x

p vent
.. (1)
Psfilter

And the leakage can be expressed as

Q leakage

K filter x

Psfilter
.. (2)
r filter

Where
r filter

= The density of gas at the operating conditions.

Ps filter

= The actual static over pressure in electrostatic Precipitator.

The tests are conducted for different Ps filter (mmWc) conditions viz. 100, 150,
200, 250, 300 mm of WC by suitably varying the damper control of the fan.
Calculate K filter from the known values of equation (1). A plot is drawn between K
filter and Ps filter. This plot will be a curve as shown in enclosed sketch. It may be
inferred that K filter is a constant.
8.4

MODEL CALCULATION
Q leakage

K filter x

Q Leakage

= m3/s

r filter

= kg/ m3

Ps filter

= kg/ m3 (mmWC)

Ps filter
r filter

Assume the following values for calculation purposes.

K filter

= 0.03

r filter

= 0.862

Ps filter

= 200

Q leakage

K filter x

Psfilter

200
= 0.457 m3/s

=0.03 x
r filter
Leakage per precipitator

0.862

0.457 m3/s

This value of Q leakage is also cross checked from the venturimeter calibration
curve for the corresponding value of pressure drop across venturi.
9.0

COMPLETION CRITERIA:
The tests are conducted for different Ps filter (mmWc) conditions viz. 100, 150,
200, 250, 300 mm of WC by suitably varying the damper control of the fan.
Calculate K filter from the known values of equation (1). A plot is drawn between K
filter and Ps filter. This plot will be a curve as shown in enclosed sketch. It may be
inferred that K filter is a constant.