INTERNATIONAL JOURNAL OF INNOVATIVE RESEARCH EXPLORER ISSN NO: 2347-6060

ERECTION /INSTALLATION OF MECHANICAL

DEVICES &COMPARATIVE STUDY OF
ELECTRO STATIC PRICIPITATOR IN SUPER
THERMAL POWER PLANT
Siddappa Nyamagoud, Assistant Professor
Mechanical dept.
Malla Reddy College of Engineering , Hyderabad, India siddappanyamagoud@gmail.com
Nalla.Sneha, Assistant Professor Mechanical dept.
Malla Reddy College of Engineering
Hyderabad, India snehadvr@gmail.com

Abstract—The growth of any country is measured by the electrical power consummation for capita. In the
developed countries like USA, Japan there electrical power 2400 W per capita where as in India the power consummation
per capita is around 800 W In this regard the National Thermal Power Corporation (NTPC) Ltd has entered in program of
power generation to the country.
The National Thermal Power Corporation (NTPC) Ltd was set up and accelerates power development in India
since in 1975. National Thermal Power Corporation (NTPC) Ltd Kudgi to build the best 800 MW units of global standards
promoting inclusive growth.
As an inspection of the receiving and storing of material at site to build the auxiliaries (Fenced lockable open
yards and Covered lockable area in sheds inspection.) Inspection of the plant component and to control the inventory in a
site. Study the plane and procedure of installation of plant components.

The plant design parameters like collection efficiency, Specific Collection Area, Aspect Ratio etc. are determine
and comparing of above parameters between the NTPC Kudgi and National Thermal Power Corporation (NTPC) Ltd
Ramgundam is under taken.

Test the Electro Statics Precipitators (ESP) components in a ground level testing methods, Kerosene test method,
spirit and water level method, Gauge method and Alignment method etc.
The solid waste from power plant is used in making of bricks.

Keywords—ESP;super thermal power plan;NTPC;sulphuri acid plant;

I. INTRODUCTION

Coal & Hydro have been the main source of generation of electricity in power plant. A steam power plant continuously
converts the energy stored in fossil fuels like coal, oil, etc. or fissile fuels like uranium, thorium etc into shaft work and
ultimately into electricity.
The steam power plant work under principle of Rankine cycle. In an operation first energy release from burning of stem
is

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transferred to water in the Generator (Boiler) to generate steam at a high pressure and high temperature, the steam leaving
the turbine is condensed into water in the condenser, where cooling water from river circulates carrying away the heat
released during condensation. The condensate (H2O) is then fed back to the Boiler (Generator) by use the pumps, and
cycle goes on repeating itself. The water as the working medium and coal is fossil fuels to convert the bulk energy to
electrical energy.
The power plant small proportion of CO2 is produced from the world’s fossil fired in power plant by used Electro
Static Precipitator (ESP) CO2 emission can reduced.
ESPs have been carefully designed to collect more than 99.5% of particles in the flue gas from many industries. ESPs
efficiently collect particles of various sizes: large particles of 3 to 10 μm in diameter, and smaller particles of less than 1
μm in diameter.
An ESP is designed for a particular industrial application. Building an ESP is a costly endeavor, so a great deal of time
and effort is expended during the design stage. Manufacturers use various methods to design ESPs. They also consider a
variety of operating parameters that affect collection efficiency including resistivity, specific collection area, aspect ratio,
gas flow distribution, and corona power. This lesson focuses on these methods and operating parameters.
In Kudgi plant steam is generated from a once through boiler at a pressure above the critical point. If the plant
incorporates reheat and several stage of feed heating, there is about 2% gain in thermal efficiency compared with
corresponding subcritical cycle.

II. LITERATURE REVIEW

In 1905 Dr.F.G Cottrell are being commercially used Electrostatic Precipitator (ESP) and demonstrated to its (capture

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acid mist suspended in exhaust of a sulphuri acid plant). ESP then was used in a variety of applications capture of solid
particles suspended in flue gas stream of coal power plant, smelting plants of copper, zinc and lead to recover metal oxide
from fumes, and in cement plants to clean the exhaust. Since then ESP technology and application has grown tremendously,
and so is the problems associated with efficient operation of ESP. The following are major areas of investigation on flow in
an ESP.

Theoretical models on ESP efficiency Aspect Ratio

Particle migration velocity Specific Collection Area
Size of collectors and size of particles

III. METHODALOGY
LIST OF ESP CONSTRUCTION ACTIVITIES MECHANICAL ACTIVITIES
Unloading and storage of materials Shifting of materials from storage yards to site(manual and/or with material handling
equipment)Electrical connection for erection and ground assembly work Checking of civil foundation w.r.t plant layout
Checking of individual footing Erection and alignment of ESP support structure columns with bracings Checking of support
structure top plate like, its spirit level, its water level and axial & diagonals distance.
Erection and alignment of support bearings Ground assembly, alignment of casing columns and welding of casing
columns with panels and its leak testing by kerosene Ground assembly of inlet nozzles and leak testing by kerosene Ground
assembly of outlet nozzles and leak testing by kerosene Erection of assembled casing panel with columns, top/bottom
girders and its alignment/welding. Erection and alignment of collecting plate floating channel arrangement Arrangement of
collecting plate assembly jig and plate straightness checking arrangement Arrangement of collecting plate lifting frame.
Ground assembly of collecting plates with top and bottom tadpole after checking the plate straightness Erection of
collecting plate panels. Depending on height of ESP Alignment of collecting plate panels and then erection of bottom
guides/keeper bars/alignment rack
On levelled platform Ground assembly of top HV frame. Erection/Positioning of top HV frame on temporary supports
Erection/Alignment/Welding of roof plates Erection, fitting and welding of pent house Erection of support insulators and its
allied parts Fixing of rigitrode rapper rod and its alignment of support insulators Loading of HV frame and its alignment
w.r.t collecting plates Temporary/loose locking of top HV frame with casing/girder Erection of rigitrodes & its straightness
checking Fixing of rigitrode bottom guide frame Ground assembly and erection of hopper with its welding/leak test.
Alignment of rigitrode w.r.t collecting plates(corona gap)Installation of items below hopper like RAV / slide gate , if
applicable
Erection of TR sets with its ducting Erection of inlet nozzle with its GD screen Erection of outlet
nozzle with its GD screen
Installation of collecting plate rapping system Installation of rigitrode rapping system

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Erection of inlet GD screen rapping system Erection of staircase and platforms Erection of access
door level platform
Erection and welding of access doors for casing/nozzles and inside landing platform. Welding of sampling parts of
ESP inlet and outlet with approach platform & ladder Air leak test and ESP thermal insulation application ELECTRICAL
ACTIVITIE Laying of cable tray, as per drawing Earthing of all electrical items Cable laying Individual TR panels to
respective TR sets Rapper panel to Rapper coils Support insulator heater feeder to heater JB and then to respective heaters
Hopper heater feeder to heater JB and then to respective heaters Purge Air Blower feeder to Purge Air Blower Hopper
level controller feeder to level controllers Making the provision of earhting point for connecting grounding hooks at casing
and roof access doors Fixing of all grounding cables for all access doors, rapper coils
Fixing of hopper heating pads Fixing of hopper level sensors Fixing of support insulator
heaters
Fixing of thermostats for insulators and hopper heaters Installation of Rappers on ESP top
Installation of TR control panels in control room Installation of rapper panel in control room Cable
termination of all cable as per drawing

IV. RESULTS AND DISCUSION

Calculation and Comparison of ESP Overall Collecting Efficiency η = Mass of all particles retained by collector
(ESP)/Mass of all particles entering collector Deutsch Anderson equation and Matts-Ohnfeldt equation are used to find
collecting efficiency.
Table 1. ESP BASES
NTPC
S NTPC
Characteristic Parameter Ramgu
L.NO. Kudgi
ndam

GENERAL: 3*800
3*
Power Generation -1ststage
1 500M
Capacity, MW 2*800
W
– 2ndstage
Larse Fl
n aktItali
2 Manufacturer
&Toubro ana
Ltd. S.P.A
Number of electrical field
3 9 4
in series in direction of flow

4 Average bus voltage (KV) 60-95 70

Pressure drop across the

5 20 15
precipitator(mm wc)

Specific collecting plate

6 264 147.68
Area(Sq. m/m3/sec)
Overall collecting
efficiency,%
99.93 98.99
7 Guaranteed collection
99.96 99.91
efficiency,%
99.91 98.16
One of field out off
service,%

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(at
Gas temperature across
8 guarantee 10
precipitator
point
flow)

COLLECTINGELECTRO
1 DES:
Size of Electrodes 2782 905
Width(mm) 15240 13500
Height(mm) 1.2 1.5
Thickness(mm)
2 No. Of Electrode:
Per gas stream 720 312

29322(
Total active collection area
3 357068 24.340
m2
m2proj
ected)
Through
4 Type of Suspension special Hook
bolts
Discharge Electrodes:

No. Of Electrodes per gas

1 stream 4212 2700

2
Length of electrode 15960 15147

3 50NB 2.7(dia
Diameter of pipe
Pipe )
Rapping Mechanism for
Collecting Electrode:
Tumbli
Electr
ng
Type ical Single
Impulse. Hamm
ers
Rapping Mechanism for
Discharge Electrode:
Tumbli
Electr
Type ng
ical Single
Hamm
Impulse.
ers
Transformer – Rectifier
Unit

GENERAL:

Silico
n oil filled AEG-
sealed TELEF
1 Type
type UNKE
constructi N
on
91.23
2 Rating(KVA) 68
(Approx)
ONO
Insulati
3 Method of Cooling N Silicon
ng oil
oil

NTPC KUDGI

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As per Deutsch Anderson equation

As per Guarantee point

η =1- exp (-AVmo/Q)
= 1- exp (-42.3977* 250/1354)
= 99.96%

As per Design point

η =1- exp (-AVmo/Q)
η = 1-exp (-42.3977*250/1465)
=99.93% (Design Point) NTPC RAMGUNDAM

As per Deutsch Anderson equation

η =1- exp (-AVmo/Q)

η = 1- exp (-24.3*138/730)
= 98.99%

NTPC KUDGI
As per Matts-Ohnfeldt equation k=0.4

As per Guarantee point

η = 1 – exp [-wk (A /Q)] k
=1 – exp [-250(42.3977/1354)] 0.4
=89.74%
As per Design point
η = 1 – exp [-wk (A /Q)] k
= 1 – exp [-250(42.3977/1465)] 0.4
= 88.99% NTPC RAMGUNDAM
Matts-Ohnfeldt equation k=0.4
η = 1 – exp [-wk (A /Q)] k
= 1 – exp [-138(24.3/730)] 0.4
=84.12%

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NTPC KUDGI
Matts-Ohnfeldt equation

As per Guarantee point

η = 1 – exp [-wk (A /Q)] k
=1 – exp [-250(42.3977/1354)] 0.5
=93.90%

As per Design point

η = 1 – exp [-wk (A /Q)] k
= 1 – exp [-250(42.3977/1465)] 0.5

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NTPC KUDGI
Matts-Ohnfeldt equation

As per Guarantee point

η = 1 – exp [-wk (A /Q)] k
= 1 – exp [-250(42.3977/1354)] 0.6
= 96.78%
As per Design point

η = 1 – exp [-wk (A /Q)] k

= 1 – exp [-250(42.3977/1465)] 0.6
=96.23%
NTPC RAMGUNDAM
Matts-Ohnfeldt equation
=93.21%

NTPC RAMGUNDAM
Matts-Ohnfeldt equation

η = 1 – exp [-wk (A /Q)] k

= 1 – exp [-138(24.3/730)] 0.5
= 88.28%

Table 2. Collection Efficiency Estimation using the Deutsch Anderson equation andMatts-Ohnfeldt equation.

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η = 1 – exp [-wk (A /Q)] k

= 1 – exp [-138(24.3/730)] 0.6
=91.76%

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Specific Collection Area (SCA)

NTPC Kudgi

SL.NO
Matts-Ohnfeldt
Deutsch Equation.
Anderson
Equation k=0.4 k=0 k=0
.5 .6
1 Guar 99.96 % 89.74% 93.90% 96.78%
antee
point
2 Desi 99.93% 88.99% 93.21% 96.23%
gn point
NTPC Ramgundam

3 ------ 98.99% 84.12% 88.28% 91.76%

--
NTPC KUDGI
SCA = Total collection surface / Gas flow rate in ESP
= A/Q m2/1000m3/hr
= 42.3977/1354
= 37.58 m2/1000m3/hr (Guarantee
Point)
SCA = A/Q m2/1000m3/hr
=42.3977/1465
= 34.73 m2/1000m3/hr (Design Point) NTPC Ramgundam
SCA = A/Q m2/1000m3/hr
=24.3/730
=33.288 m2/1000m3/hr

Aspect Ratio (AR) NTPC KUDGI

AR = effective length of collector surface / effective height of collector surface
= l/h

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=2782+2782+2782+2782+2782+2782+2782+2782+2782/15
240 (9 no of field)
=1.64

NTPC Ramgundam AR = l/h

=905+905+905+905/13500 (4 no of field)
=0.3

V. CONCLUSION

My project being an integral part of engineering syllabus provides not only easier understanding but also helps inform an
individual with technologies.Fromtheoretical models, which differ considerably, it makes visible an individual to practical
aspect of all things. The practical exposure received here will pay rich dividends to me. I gained a lot of practical knowledge
which otherwise could have been exclusive to me.

During my project work altogether a good experience, since work culture and mutual co-operation were excellent in at
NTPC Kudgi.Moreover, fruitful support of quality control and cognizance of safety by employees were fare which is much
evident in Kudgi plant.

The change in collecting plates' size varies the overall collecting efficiency of the ESP (e.g. NTPC Kudgi 99.97% and
NTPC Ramgundam 98.99%).Increase in the SCA of an ESP design will in most cases increase the collection efficiency of
the ESP AR range 0.3 to 2for high-Efficiency ESP (those having collection efficiency of greater than 99%). The AR should
be greater than 1 (average 1 to 1.5) and (e.g. NTPC Kudgi 1.64 and
NTPC Ramgundam 0.3).

SCOPE FOR FUTURE WORK

The performance of other auxiliaries of thermal power plant can be studied thourghly and there is scope for improvement
in the efficiencies of varies auxiliaries of power plants.

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VI. REFERENCES

1[] er.pdf.
[2] Executive Summary (2011), International Energy Agency,
http://www.iea.org/Textbase/npsum/solar2 011SUM.pdf.
[3] Glassley, William E. (2010). Geothermal Energy: Renewable Energy and the
Environment, CRC Press, ISBN 9781420075700.
[4] Co-firing of Biomass Residues for Electricity Generation in Grid Connected Power
Plants (2009), CDM Executive Board, http://cdm.unfccc.int/EB/051/eb51_repan0 5.pdf.
[5] Key World Energy Statistics 2015 - International Energy Agency
https://www.iea.org/publications/freepubli

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I. CONCLUSION
Very limited experience has been gained in gasification of biomass residues. Most extensively used and
researched systems have been based on downdraft gasification. At present no reliable and economically feasible systems
exist. Biggest challenge in gasification systems lies in developing reliable and economically cheap cooling and cleaning
trains. Maximum usage of producer gas has been in driving internal combustion engine, both for agricultural as well as for
automotive uses. However direct heat applications like grain drying etc. Are very attractive for agricultural systems.
By using this Down draft wood gasifier the emissions of a engine with petrol got carbon monoxide
7.8%,carbon dioxide 12.56%.oxygen 18%, where as wood gas emission got carbon monoxide 6%,carbon dioxide
15.28.oxygen 22%,wood gas blends with petrol got emissions has got carbon monoxide 5.8%,carbon dioxide 16%.oxygen
20%.A spark ignition engine running on producer gas on an average produces 0.55-0.75 kWh of energy from 1 kg of
biomass. Compression ignition (diesel) engines cannot run completely on producer gas. Thus to produce 1 kWh of energy
they consume 1 kg of biomass and 0.07 liters of diesel. Consequently they effect 80-85% diesel saving.
Hence by using this emission analysis conclude that wood gas becomes a future alternate fuel and this gas not
harmful the atmosphere compare to petrol and diesel.

II. ACKNOWLEDGMENT
I feel great pleasure in submitting this Paper on “WOOD GAS GENERATOR WITH INTEGRATED BIOLER FOR FUELING
INTERNAL COMBUSTION ENGINES BY
USING WOOD PYROLYSIS”. I wish to express true sense of gratitude towards my Principal Dr. P.John Paul. And a special thanks to
my H.O.D Shashikanth and Guide Dr.Velmurugan who at very discrete step in preparation of this Paper contributed his valuable guidance
and help to solve every problem that arise. Also, most likely I would like to express my sincere gratitude towards my parents for always
being there when I needed them the most. With all respect and gratitude, I would like to thank all the people, who have helped me directly
or indirectly. I owe my all success to them.

III. REFERENCES AND FOOTNOTES

1. Imbert gasifier first wood gasifierb .Imbert in1880

2. Kjellström, B. 1984. Hazards of producer gas operation: The Beijer Institute, Stockholm,Sweden.

3. Kaupp, A. 1982. The gasification characteristics of rice hulls for the generation ofelectricity and shaft power on a small
(530 hp) scale, 1st Int. Prod. Gas Conf., Colombo, SriLanka.

4. Kissin, I. 1942. Gas producers for motor vehicles and their operation with forest fuels,Imperial Forestry Bureau, Oxford,
U.K.

5. Axelsson, R. 1969a. Summary of laboratory tests

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withproducer gas operation of tractorMassey Ferguson 1100 (in Swedish). StatensMaskinprovningar, Umea, Sweden.

6. Axelsson, R. 1969b. Sweden. Summary of tests with producer gas truck Scania L80
(inSwedish).StatensMaskinprovningar, Umea,

7. Bailey, M.L. 1979. Gas producers for vehicles - An historical review. Department
Scientific and Industrial Research, New Zealand.Rep. No.CD 2279.

8. Baja, L. 1983. Promotion of producer gas projects in the Philippines. Ibid.

9. Forest utilization contracts on public land, 1977 (E* F* S*)

10. Planning of forest roads and harvesting systems. 1977 (E* F* S*)

11. World list of forestry schools, 1977 (E/F/S*)

12. The marketing of tropical wood in South America, 1978 (E S*)

13. National parks planning, 1978 (E* F* S***)

14. Forestry for local community development 1978 (E* F* S*)

15. Wood chips, 1978 (C* E* S*)

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