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CONTENT

1. PURPOSE

2. SCOPE

3. REFERENCE DOCUMENT

4. GENERAL DESCRIPTION AND BRIEFING OF EQUIPMENT

5. SAFETY PRECAUTION

6. PREE COMMISSIONING

7. COMMISSIONING TEST

8. INTERLOCK

9. DOSING PHILOSHOPHY

10. ATTACHMENT

PURPOSE

Purpose of this commissioning procedure :

1.1 To get optimum performance of ESP, to prevent failure and serious damage at
equipment while commissioning

1.2 To check and ensure that electric and I&C interlock, protection and signal devices
can operate correctly.

1.3 Inspect equipment operation and check out system performance. Find and repair
defects that might exist.

1.4 This procedure should be applied for test and commissioning of ESP Boiler unit 1
and 2 PLTU Sebalang Lampung.

1. SCOPE
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Commissioning of Electro Static precipitator and its system after the individual test of
all ESP equipment completed. This Commissioning includes mechanical and electrical
equipment test.

2. REFERENCE DOCUMENT

Zheijiang Fieda Environmental Science and technology co.,Ltd

3. GENERAL DESCRIPTION AND BRIEFING OF EQUIPMENT

3.1 GENERAL DESCRIPTION

Coal Fired Power Plant 2 X 100 MW PLTU Sebalang, Lampung consist of Bolier
unit 1 and 2, each Boiler is equipped with two ESP, there are double chamber, each
chamber consist of 3 field, 3 Transformer Rectifier on the top side and 3 Ash hopper
at the bottom side. Emitting and collecting electrode are verticall arranged inside
every field and equiped with Emitting and collecting rapper system to remove ash
partikel.

Inlet nozzle are installed between inlet flue gas duct and ESP inlet casing, there are 2
layer of gas distribution screen installed inside inlet nozzle to make flue gas passing
enter the ESP Field as uniform as possible.
Out let nozzle installed at out let line of ESP casing to let the clean flue gas go into
the exhaust flue gas duct

3.2 OPERATIONAL PRINCIPLE OF ESP

The principle of dust collection of ESP as follow :
When passing through the high voltage electric field, dust particle in the gas was be
charged by colliding with positive ions, negative ions and electrons or in the ion
dispersion movement. The particle with electrons and ions will be move, under the
influence of electric force,toward and lather will be accumulate on the electrodes of
opposite polarity. By means of rapping, the layer of dust particle on the electrodes
will be disloged into the bottom hopper.

3.3 BRIEFING OF EQUIPMENT

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Structural in ESP divided into two portions, electric portion and mechanical portion.
Their main componens and functions are described below :
4.1 Electrical portion
The electrical porttion consist of high voltage DC power source (including its
control system) and low control system.
4.1.1 conventionally we use Model GGAJ02 high voltage power source. Design
of the model is follow :

Such a set of device usually includes high voltage transformer rectifier, auto
control cabinet and reactor of high voltage transformer rectifier and auto
control cabinet. The power source can automatically adjust the voltage applied
to the electric field according to change of gas conditions there in and can
adjust spark ratio in the field to optimum level to the high result of dust
collection can be achieved. This power source is equiped with perfect
interlocking protective system.

4.1.2 Low voltage control system alarm and its functions :

a. Program control of auto collecting and emiting rapping
b. Heating and heating temperature control of high voltage insulations
c. Ash level check and alert control
d. Control of ash discharge and ash conveying
e. Control ofsafety interlock of doors, holes and cabinets
f. Control of hopper electric heating
g. Measurement and display of inlet and out let gas temperature
h. Setting of function and parameters for LV system through host computer
I. Display and integrated signal and alarm device.
Note : Above function are selected according to requirements.

4.2 Mechanical Portion

This portion can be divided structurally into internal, casing and auxiliaries.

4.2.1 Internals
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Consist of :
a. Collecting system
b. Emiting System
c. Correcting Rapping System
d. Emiting Rapping System

4.2.2 Casing
Consist of :
a. Inlet Nozzle
b. Outlet Nozzle
c. Roofs
d. Casing
e. Hopper and hopper Ridge beam.

4.2.3 Auxiliaries
Consist of :
a. Stairs and platforms
b. Support Bearings
c. Thermal insulation
d. Earthing

4. SAFETY PRECAUTION
All the commissioning personnel must have the general knowledge of savety and a
special requirement must abide by standard JB6407.
Necessary safety measures before commissioning test :
1. Commissioning condition is qualified, Engineering installation meets requirements of
design and pass acceptance.
2. Relevan test site field is leveling, without sundry, road is clear, normal/accident
lighting is equipped completely
3. There is reliable and rapid communication method
4. Make sure that all personnel leave ESP interior and other HV dangerous area
5. Relevan charged rooms door shall be locked, electrical equipment shall have
obstruction and relevant warning boards shall be hung
6. Fire fighting device shall be arranged according to relevant provision
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6. PREE COMMISSIONING
Installation, Check and adjustment of equipment
6.1. The installation of equipment should met the requirements ESP Isntallation manual.
6.2. Check and adjustment of equipment
Respective check and adjustment should made to the electric and mechanical portion
After equipment erected prior to it being to put into operations.

6.2.1 Check and adjust of Mechanical portion

6.2.1.1 second corrections of any deformed or bend collecting plates and discharge
Wires within lelctric fields to ensure all the distance between opposite electrode are
Kept within following deviation
6.2.1.2 Make adjustment in the electrif fields wherever the distance between emitting
And another insulated parts is less than distance between opposite electrodes.
6.2.1.3 Check all the bolt and nuts to see that they are properly tightened and welded dead
6.2.1.4 Check to see that the contact position between the rapping hammer and anvils
Are exactly as required by the approved drawings and the shaft and hammers can
Rotate freely.
6.2.1.5 Removed all foreign materials left with in electric fields.
6.2.1.6 Check to see that motor for dampers, rapping, ash discharge, etc. have correct
Direction of revolution, that they can turn freely, that the chain are mounted with
Proper tension and that all locations calling for lubrication have been oiled and
Greased.
6.2.1.7 Check to see that all insulators are mounted steady, under evenly disturbed load
and kept dry anclean.
6.2.1.8 Check to see that the different part of ESP casing and all inspection doors are
properly sealed. Make gas tightness test as per Annex B of ESP installation
manuals.
6.2.1.9 The Rapping is design ofn principle of improving the dust dislodging effect,
reducing dust re – entrainment, enhancing collection efficiency, lengthening the
life span of rapping elements etc. for details refer to ESP electric technician
agreement of the project. After period of trial run, rapping system is adjusted to its
optimum mode.
6.2.1.10 Check and ensure all of ash pneumatic system under hopper of ESP already tested
and function well.
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6.2.2 Check and adjust of Electric Portion

6.2.2.1 Measure the aroun of resistance of the esp proper and see that its less than 2 ohm.
6.2.2.2 Use a 2500V mega meter to measure the insulation resistance of the high voltage
insulators and make sure it is larger than 500 megaohm
6.2.2.3 Thecablebetween ESP casing and positive terminal on the high voltage transformer
rectifier shoul be in good order and family secured.
6.2.2.4 Use a 500V mega meter to measure the insulation resistance of all motor and their
cables and make sure that its not less than 0.5 megaohm.
6.2.2.5 Check to see the operating mechanism in the high voltage isolating switch gears has
high mobility and can be set to exact position.
6.2.2.6 Check to see that all wiring between the electric part is correctly laid as per
approved product drawing.
6.2.2.7 Adjust the spark frequency in accordance with the electric conductivity of the flue
gas and the required collection efficiency.
6.2.2.8 Set the value of the thermostat for insulator heating is normally 15 – 25 C above the
flue gas dew point.
6.2.2.9 The electric control circuit are areto be adjust according to thespecified rapping
andash discharge system.
6.2.2.10 For various item in electric commissioning, such as LV control loop, HV control
loop, no load voltage step – up test, coldtrial run, hot load run, etc. refer to annex B
in the ESP installation manual or the introduction provided by manufacturers of
electric control systems.

7. COMMISSIONING TEST
7.1 Tested items and specific operation
7.1.1 Dummy Load test
7.1.2 Protection punction test
- Safety interlock protection
- Short circuit protection test
- Open – circuit protection test
- Oil temperatureprotection test
- Gas protection test

7.1.3 Commissioning of Emitting and Collecting rapper device

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Make sure that motor running direction is accurate when rapper motor is energized
and test running. Make sure that it is in good waiting operation condition after
operating for 2 hours.

7.1.4 Energized Commissioning of Electric Heater

Start electrical heater andcheck whether electrical heater system in normal.
7.1.5 No – Load Voltage rise test of field
- Test Objective
Do cold state no load test before
ESP thermal state operation to make sure the realiable operation of ESP. this is
used to inspect field (especially distance quality of emitting and collecting plate)
and installation quality of electronic control part, to inspect insulating property of
cable and electrotechnical porcelain piece, to check electrical control performance
and reability ofelectrical element.

- Test conditions
1. Throught inspection and commissioning of above item ands reach
requirement of commissioning.
2. Its not rainy, foggy or strongly windy
3. Make sure that all person have left field andother HV areas
4. All the manhole door are locked and safety measures area implemented.

- Test Procedure
1. Organize relevan personnel about test andsafety supervisory personnel. There
shall be special assigned person to supervision at the position ofmanhole door
and HV inducting insulated switch.
2. Make sure that its commanded unitedly by commander in chief, assign duty
for each person and its implemented term by term.
3. Put insulator heating system into action (8 hours in advance)
4. Start firstly and then close fan after nature air passing throught field, so as to
remove ozone, moisture and etc.
5. Do static no loac field voltage rising test firstly and then go on dynamic no
load field voltage rising commissioning.

- Test contents
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At the static and dynamic condition, measure voltage value of each field atdifferent
secondary current separately and draw V – I characteristic curve.

- Static no load voltage rise test of field.

Do the static no load field voltage rising test when ESP rapper system in not
started, fan is not run, field is in static condition and there is no inletting gas.
1. HV insulated switch is converted to field power position. Pause momentarily
when reaching 40 kv during field voltage rising, we use HV electroststic meter
to measure HV insulated switch and contack control room to proofread
secondary meter. Rise to rate value of secondary current again and proofread
secondary amperemeter and volt meter.
2. Secondary current is declined by 100 mA each time from peak to zero and
record primary and secondary current and voltage every time.
3. Pay attention to distinguish of conditions of field flashover, unwanted
operation of controller and etc. during whole process. Check body condition if
there is any abnormal phenomena.
4. Removefailure in time during voltage rising andmake power supply and field
in normal condition.
5. Raw V – I characteristic curve of static no-load field.
- Dynamic no load voltage rise test of field
Do dynamic no load voltage rising test when there is no inletting gas, HV and LV
electrical equipments are in action.
Test metode is same to static no load field voltage rising test. Record maximum
current andvoltage value. Have a comprehensive review on operational condition l
of noof each working circuit if condition is permitted. Solve problems timely if
any.

Reference value of no-load breakdown voltage when heteropole distance is differ

Heteropole distance
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8. INTERLOCK
a. Flow, Temperature and Pressure
a) Inlet Flow meter – the inlet flow meter can detect that the flow is in the correct
range. Should the flow fall out of the correct range the rectifier should shut
down immediately followed by the rest of the system.
b) Flow Switch on outlet of electrolyser – should the inlet flow meter be
indicating the correct inlet flow but the flow switch on the outlet detecting no /
low flow, the rectifier should shut down immediately followed by the rest of
the system. This could indicate a burst pipeline somewhere downstream of the
main flow meter and/or a faulty inlet flow signal.
c) High Outlet Temperature – a high outlet temperature may mean the flow has
dropped below a certain level and/or stopped completely. With the rectifier
running in a low flow situation heat will very quickly develop in the
electrolyser cells. The rectifier should shut down immediately followed by the
rest of the system.
d) High Differential Temperature – a high differential temperature (inlet to outlet)
may mean the flow has dropped below a certain level and/or stopped
completely. With the rectifier running in a low flow situation heat will very
quickly develop in the electrolyser cells. The rectifier should shut down
immediately followed by the rest of the system.
e) High Inlet Temperature – this is not normally a problem on seawater systems,
however, the inlet temperature should be below a certain point to prevent
deformation of the PVC pipework. If over a certain level the rectifier should
shut down immediately followed by the rest of the system.
Point List

Temperature Set Point /Range Unit Action

Normal Inlet Temperature 15– 32 ºC System continues

Low Inlet Temperature Alarm <15 ºC running

Warning Alarm
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Shut Down System,

Low Inlet Temperature Trip <10 ºC
Alarm
High Inlet Temperature Alarm >35 ºC Warning Alarm
Shut Down System,
High Inlet Temperature Trip >40 ºC
Alarm

Normal Outlet Temperature 15– 36 ºC System continues

running
Low Outlet Temperature Alarm <15 ºC Warning Alarm
Shut Down System,
Low Outlet Temperature Trip <10 ºC
Alarm

High Outlet Temperature Alarm >38 ºC Warning Alarm

Temperature Set Point /Range Unit Action

Shut Down System,
High Outlet Temperature Trip >43 ºC
Alarm
Normal Differential Temperature 1.5 –4 ºC System continues

Low Differential Temperature <1.5 ºC running

Warning Alarm
Alarm Shut Down System,
Low Differential Temperature Trip <1 ºC
Alarm
High Differential Temperature
>4.5 ºC Warning Alarm
Alarm
Shut Down System,
High Differential Temperature Trip >5 ºC
Alarm

Flow Set Point / Range Unit Action

Normal Inlet Flow 25 ‐ 35 m³/hr System continues

running
Low Inlet Flow Alarm <25 m³/hr Warning Alarm

Shut Down System,

Low Inlet Flow Trip <22 m³/hr Alarm (sea water
booster failed to star)
High Inlet Flow Alarm > 35 m³/hr Warning Alarm

Shut Down System,

High Inlet Flow Trip > 37 m³/hr
Alarm
System continues
Normal Outlet Flow (Switch) On m³/hr
running
Shut Down System,
Low Outlet Flow Trip (Switch) Off m³/hr
Alarm

b. Rectifier Alarm
- Rectifier Key Switch Change (if the system already running)
Action :
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“Rectifier shut down, Seawater Booster Pumps and run flush 20 seconds
then stop, Alarm on HMI Rectifier Key Switch Change Position & EC Plant
Failed”
- Rectifier Thyristor Over temperature, Rectifier Phase Failure, Rectifier Fan
Failure, Rectifier Door Open, Rectifier over voltage, Rectifier Transformer
Over temperature, Rectifier Over Current trip.
Action :
“If rectifier not running – Appropriate Alarm on HMI”
“If rectifier is running ‐ Rectifier shut down, Seawater Booster Pumps run and
flush 20 seconds then stop, Alarm on HMI Rectifier Key Switch Change
Position & EC Plant Failed and appropriate Alarm on HMI”

c. Storage Tank (60m³)

Point List

Tank Parameter Level (%) Action

Stop dosing pump (starter circuit),

High High ( Imminent Over Rectifier shut down, sea water
X%
Flow) booster pumps 20s then stop.
Alarm, EC plant failed
System will try and hold this point
100 % 100 % to ensure sufficient capacity for
Shock Dosing
(when shock dosing , system will
0% 0% pump to this level 0 – 10 %)
The sea water booster pump to

d. Chlorine Analyzer
The chlorine analyzer will be transmitted to the PLC and system will try and
maintain set point of CI2 residual at concentrate 0,2% (2000 mg/l) of NaOCL by
varying the current output from the rectifier for electrolyser and manipulated dosing
rate of the dosing pump (Variable Speed Drive)
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9. DOSING PHILOSOPHY
a. Normal Dosing
The required normal dosing rate is 1.2 ppm, one dosing pump will be running on the
variable speed drive at pumping capacity of 27.029 m³/hr to maintain 1.2ppm.
b. Shock Dosing
The shock dosing philosophy will be 3 times per day for 15 minutes to a level
4ppm,and time between for shock dosing is 8 hours.
The shock dosing will be drawn from the storage tank by running 2 of the dosing
pumps in parallel, to reach 90.096 m³/hr in 15 minutes of CI2.
Variable speed drive at dosing pump will take each pump to pumping output
capacity of 90.096 m³/hr / 2 = 45.048 m³/hr each dosing pumps.

10. TECHNICAL SPECIFICATION

a. ELECTROLYZER
Train No : OXIMAX MCC60000/6
Cell Model No : OXIMAX MCC10000
Volt at Rated Output : 67.5 V
Amp. at Rated Output : 3500 A
Power Supply Requirement : 81 V DC
Power Supply Requirement : 3800 A

b. RECTIFIER
Serial no : 10227
Manufactured : AET ELECTRIC Pte LTD.
Rated Power : 308 Kw
AC Input Voltage : 380 V
AC Input Current : 400 A
DC Output Voltage : 81 V
DC Output Current : 3800 A

c. SEA WATER BOOSTER

Motor
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Serial No : 9FWC0291 /9FWC0332

Manufactured : CMG PPA160M
Power : 11 Kw
Current : 20.2 A
Rpm : 2930

Pump
Manufacture : Corro Pump SA.
Type : Centrifugal
Head : 40 m
Capacity : 43 m³/hr

d. CHLORINE DOSING PUMP

Motor
Serial No : 9CWC 06910 / 9CWC 0691
Manufactured : CMG PPA132S
Power : 7.5 Kw
Current : 14 A
Rpm : 2940

Pump
Manufacture : Corro Pump SA
Type : Centrifugal
Head : 21 m
Capacity : 50 m³/hr

11. ATTACHMENT