Transforming the Future of Power Technology

Product Bulletin

Transformer-Rectifier Sets for Electrostatic Precipitators

Custom-designed convenience and economy for retrofit applications
Transformer-Rectifier (T/R) sets supply NWL specified DC voltage and current to electro- bushings,T/R with top double halfstatic precipitators. NWL makes both stanwave 48 KVA, 55 KV DC, 1 60 Hz dard and custom T/R sets, and both set the worldwide standard for quality and adaptability in retrofit applications for ESPs. NWL T/R sets and associated control systems meet all electrical and mechanical requirements for all ESPsAmerican, European and Japanese. Standard designs exist for Westinghouse, General Electric and generic ESPs. As with all NWL products, custom designs are available to meet individual requirements. RTEmp Fluid-filled T/R Set with side-mounted Both standard and custom units are crafted high-voltage bushing, external ground switch and CLR in junction box. to minimize installation time and expense for example, by matching your existing installation, connection for connection; or, when necessary, by arriving preconfigured to withstand corrosive environments. Moreover, T/R sets can be unitized with NWL control systems for rapid installation. Packages in this configuration include everything necessary to energize a standard ESP. While design, ratings and form factors may vary, NWL T/R sets and controls are in operation throughout the world, on virtually every major type of precipitator.

Features and Benefits

I Convenience and economyNWL T/R sets are specifically designed for safe, rapid installation, operation and maintenance: Physical connections match existing bus duct, base mounting and low voltage connections. Electrical and mechanical characteristics meet all requirements specified for your ESP. When corrosive environments are a concern, NWL offers a range of available options designed to protect the T/R sets before installation. Unitized T/R sets and control systems ensure rapid installationsimply set them in place and plug in primary power.

NWL 312 Rising Sun Road Bordentown, New Jersey 08505 USA Tel: 1 800 742-5695 Fax: 609 298-1982 www.nwl.com NWL Europe via per Ghevio n19 28046 Meina (NO) Italy Tel/Fax: 390-322-669914 E-Mail: TEMA-NWL@intercom.it NWL Pacific 253-9, ShinKee-Ri Seowoon-Myun Anseong-Si KyungKee-Do 456-850 Korea Tel: 82-334-6726240 Fax: 82-334-6726246

Product Bulletin The Transformer-Rectifier SetProduct Description

T/R sets supply specified DC voltage and current to ESPs. The T/R high-voltage supply consists of a transformer, an optional current-limiting reactor, rectifiers and switchesall contained in an oil-filled tank that is completely sealed and suitably painted for outdoor use. Standard semi-outdoor bushings are supplied on these units and are suitable for outdoor use when enclosed in a bus duct to protect them from the elements. The following sections describe each T/R component in detail. I Transformer-Rectifier TankT/R tanks are cylindrical or rectangular in shape and designed to withstand 7 PSIG test pressure. An important feature is the clamped handhole cover, which facilitates quick and thorough field servicing. Lugs and supports are available to aid in lifting by crane or forklift. An outdoor paint system is standard, but NWL can meet other, individual specifications on request. I Low-Voltage Junction BoxLocated on the outside of the T/R tank, this box houses all low-voltage input bushings and metering feedback bushings, as well as the terminal board for the temperature gauge alarm contacts and terminals for the optional primary voltage metering. I Main transformerThis is a high-voltage, step-up transformer designed to convert low-voltage input into the high voltage required for ESP operation. The transformer is located on the bottom of the tank. Primary is designed to match the type of controller being used; secondary voltages and currents are set to meet load requirements. To date, NWL has designed output voltages up to 130 KV. The transformers unique design helps prolong its life by distributing the electrical and mechanical stresses incurred in operating the ESP. I RectifierTo ensure optimum reliability, NWLs minimum rating for high-voltage rectifiers is180 KV PIV. As a result, Mean Time Between Failures (MTBF) is extremely highand, by extension, process downtime is minimal. A full-wave rectifier bridge is connection across the transformer secondary. The negative polarity DC output from the rectifiers is connected either to a two- or a five-position switch. The rectifiers are mounted on plug-in modules that can be easily removed and replaced through the top handhole cover, should maintenance be required. I Current-Limiting Reactor (CLR)Because of sparking and consequent short-circuiting during ESP operation, current must be limited to protect the T/R set. When a Silicon Controlled Rectifier (SCR) controller is used as the voltage-regulating device, it must be protected from adverse short-circuit conditions. Besides improving waveform and waveform factor, the CLR protects both the T/R set and SCR controller as follows: By limiting current to the SCR By limiting peak current to the T/R set during precipitator sparking The CLR is designed so that short-circuit current is limited to a value specified by the user or ESP manufacturer (usually a maximum of three times rated current). The CLR is connected in series to the T/R set primary. By using a CLR, less inductive reactance is required in the high-voltage transformer, thus allowing for greater economy in transformer construction. Use of a CLR also allows more efficient utilization of SCR devices, without which a higher current carrying SCR devices would have to be used, because of derating for lower conduction angles. CLRs are individually designed to match the load specified by each customer for particular ESP requirements. Location of CLRs can be as follows:

NWL Current Limiting Reactor (CLR) 1, 60 Hz, 3.3 MH, 160A

Product Bulletin

Inside the T/R tank In a NEMA 3R low-voltage junction box attached to the T/R tank In the SCR controller cabinet In NEMA 1 or 3R cabinets designed to contain only the CLR Specific electrical requirements for CLRs, such as taps or unusual ambients are also uniquely designed by NWL engineers. On some smaller ESPs, in which response time is not critical, a NWL saturable-core reactor may be used instead of a SCR control. The necessary systems current-limiting function may then be satisfied by the impedance designed into the SCR, thus eliminating the need for a CLR. I Air Core InductorOne air core inductor is installed in series with each high-voltage DC output bushing to limit high-frequency capacitance discharge current surges generated during sparking in the load. I High-Voltage SwitchBecause NWL offers a single HV bushing full-wave unit and a double HV bushing half-wave unit, two high-voltage switches are available. (Units can also be provided without switches.) These switches are designed for T/R operating mode configuration only and should not be used as the only safety grounding devices. All grounding for access to high-voltage circuits must be performed in strict accordance with the National Electric Code, which includes the use of grounding sticks to avoid personal injury. The high-voltage, five-position switch is an oil-immersed, externally operated off-load switch that performs the following functions for double half-wave sets:
High Voltage Bushing A B
Customized T/R Set with an external, 4-position ground switch.

Switch Position 1 Ground Ground 2 Full Wave Ground 3 Full Wave Full Wave 4 Half Wave Half Wave 5 Ground Full Wave

This unit is provided with a mechanism to interlock switch per customer requirements for safety purposes. Up to three locks can be utilized on this mechanical interlock system. The high-voltage, two-position switch for full-wave T/R sets is an oil-immersed, externally operated off-load switch. Its functions are as follows:
Bushing B Switch Position 1 2 Ground Full Wave Output

Both the two- and five-position switches are readily accessible through the handhold cover. I Air-Switch OptionTop-mounted or side-mounted air grounding switches are also available as optional accessories for NWL T/R sets. These switches enhance the reliability of T/R sets and provide for visual checks on switch position through a window in the switch housing. Interlock provisions are also provided. I Visible Disconnect/Ground Switch OptionThis is a four-position, external disconnect ground switcha splitter switch developed to supply power to two separate precipitator fields from a single-bushing T/R (thus splitting the power into two fields). Major benefits offered by this option are Increased reliability over double-bushing T/R sets, since field energy bypasses internal components of a T/R when an electrical imbalance exists between the two fields, or when random sparking occurs Allows operators to view switch positions through the switch window built into the housing

Product Bulletin
Improved precipitator sectionalization over a full-wave T/R (Sectionalization equals that of a double-bushing housing.) Compact size allows for easy installation in retrofit applications The splitter switch modes of operation are
Field A B 1 Ground Ground Modes of Operation 2 3 Full Wave Full Wave Ground Full Wave 4 Ground Full Wave

I High-Voltage BushingsThe single- or double-bushing arrangement described above can be mounted on either the top or the side of the tank. Normally, these bushings have negative polarities, but a quickly reversible polarity provision can be supplied. NWL can also make provisions for a high-voltage bus duct flange, if required. I Liquid Level GaugeCoolant level is indicated by a large, easy-to-read dial-type gauge utilizing magnetic coupling to ensure accuracy. Convenient readout helps prevent downtime due to leaking seals. NWL can also supply optional NO-NC contacts. I Temperature GaugeA dial-type temperature gauge with its own independent well (for easy replacement in the field) measures actual oil temperaturenot just the surface temperature of the tank. This more meaningful data can then be relayed through optional NO-NC alarm contacts to a terminal board for local or remote alarm actuation. I Pressure/Vacuum GaugeAn easy-to-read, dial-type gauge is available as an option. Mounted on top of the tank, it indicates pressure/vacuum changes within. NO-NC alarm contacts are also available. I Voltage Multiplier and Surge ArrestorTo facilitate use of a voltometer, a voltagemultiplier network is standard equipment. This network is supplied for each high-voltage bushing and consists of high-quality, high-voltage, series-connected resistors suitable for electrostatic precipitator operation. One end of the network is connected to the high-voltage bushing; the other end is connected to the low-voltage terminal and then to ground, through a surge arrestor. The meters should be connected across the surge arrestors, which prevent buildup of unsafe voltage levels if the metering circuit opens. I Connections: (A) Grounding Pad: A 1/2-13 threaded boss is welded to the front of the tank for grounding the T/R set to the system (B) Quick-Disconnect Connections: These amphenol-type connectors provide positive, vibration-proof connections as well as a quick-disconnect feature for field servicing. They are standard on the following: Five-position and two-position high-voltage switches Voltage multiplier network terminations High-voltage bushing connections to the rectifier. I Insulating FluidAll T/R/ sets are vacuum impregnated and filled with either oxidation-resistant mineral oil, silicone fluid (dimethyl silicone), or R Temp and ALPHA 1 fluids, classified as a less flammable hydrocarbon. I Fluid DrainAll tanks are equipped with a 1/2-inch gate valve (with plug) for draining and sampling dielectric fluid. I Top Fill HoleEach T/R/ set is supplied with a 1/2-inch NPT fill hole with a pressurerelief device screwed into the fill hold. This assembly is located on top of the T/R. By removing the pressure device, coolant can be added as necessary.

NWL T/R Set with topmounted bushing and external ground switch 65 KV, 1,000 MA

Product Bulletin

I T/R Sets for Corrosive EnvironmentsMany T/R sets must operate in highly corrosive environments. To meet these requirements and reduce equipment maintenance, NWL offers the following alternatives: Tanks fabricated from 304L or 316L stainless steel Our best anticorrosive paint system, which utilizes inorganic zinc primer for cathodic protection, followed by a high-build epoxy primer and an aliphatic polyurethane top coat. Material and pretreatment to SSPC-SP 8, blasted surface preparation in accordance with SSPC-SP-5, and a paint system that conforms to SSPC-SP-12 Anticorrosion paint system of zinc-rich primer and epoxy top coats. Material and pretreatment to SSPC-SP-8, blasted surface preparation in accordance with SSPC-SP-10, and paint system that conforms to SSPC-SP-12 The above systems are all fabricated in-house for assured quality control.

Transformer-Rectifier and Control Package

NWL manufactures a unitized T/R and control package for industrial applications. This design includes all the electrical components necessary to energize a standard ESP. In this configuration, the control portion of the power supply is mounted on the side of the T/R. All wiring between the two components is done and tested at the factory. Both the T/R set and the controller are NEMA 4 rated for outdoor use. This approach significantly reduces installation time. Once set in place, the system is energized simply by connecting to primary power.

Transformer-Rectifier control package 55 KV, 750 MA, 59 KVA

Single-line schematic for a T/R-control package. This design is simple, reliable, and compact. Remote displays are available to easily monitor the system from the control room.

Transformer-Rectifier control panel 55 KV, 750 MA, NEMA 4 enclosure

ET125 9/00