ELECTRO STATIC

PRECIPITATOR
OPERATION AND MAINTENANCE
DUST COLLECTING EQUIPMENTS

 Function of the ESP is to collect the dust in the

flue gas.
 Other dust collecting equipment's are
– Mechanical dust collectors
– Bag filters
– Scrubbers
– Cyclones
ESP WORKING PRINCIPLE

 The ESP works on the principle of Corona effect.

 There is a Transformer Rectifier set which gives a

high DC output .(kV and mA)

 The –ve terminal of the TR set is connected to the

Rigitrode system and the +ve terminal to the
collecting plates which are already earthed.

 Due to the high potential difference, the –ve ions

move from the Rigitrodes to the collecting plates.
This is called CORONA EFFECT.
ESP WORKING PRINCIPLE
Electrical charging of particles.
 Migration of charged particles to
grounded collecting plate surface.
 Removal of accumulated particles
from the collecting surfaces by
mechanical impact (Rapping).
ESP WORKING PRINCIPLE

 The dust particles surrounding the –ve ions will

also get –vely charged and thereby they get
collected on the Collecting plate.

 As the dust deposits on the collecting plates, the

charges of the dust get discharged.

 Now by rapping, the dust is dislodged from the

plates.
ESP WORKING PRINCIPLE
Rapping

Collecting
plate
Separated
Neutral dust
dust

Charged
dust
-ve ions

Discharge electrode

TR Set
ESP Construction details

 The ESP consists of the following parts:-

1. Inlet Nozzle
2. Four mechanical fields-(One TR SET per
field)
3. Outlet nozzle
4. Pent house
5. Hopper-(One hopper per field)
6. Rapping system
 ESP Construction details

 INLET NOZZLE:-
– Inlet nozzle consist of three gas
distribution screens (Perforated screen)
– These screens are provided to distribute
the flue gas uniformly inside the ESP.
– There is a rapping system provided for this
GD screen.
ESP Construction details

 FIELDS:-
– The ESP is having four mechanical
fields and four electrical fields. (i.e each
mechanical field is having an
independent TR set)
– Each TR set is of rating 1500mA and
120kV
– Each field has gas passages.
 Rigitrode

Collecting plate

Gas passage

High voltage frame

INTERNAL ARRANGEMENT OF ESP

 ESP Construction details
 PENT HOUSE:-
– There is one common pent house .
– The suspension arrangement for the high voltage
system is inside the pent house. (Insulator assembly)
– The HV system is four point suspension.
– There is one purge air blower with a heater on top of
the pent house. This will pressurize the pent house
and keep the inner wall of the support insulators free
from dust deposition.
– There is an Insulator heater provided for all
individual support insulators to maintain the
temperature of the insulators above 90Deg.C. These
heaters are controlled by a thermostat (trip at
temp.>90deg.c)
 ESP Construction details

 RAPPING SYSTEM:-

 The rapping system is known as EMIGI rappers. (Electro

Magnetic Impulse Gravity Impact )

 There are three types of rapping system:-

1. Rapping system for inlet nozzle
2. Rapping system for Collecting plates
3. Rapping system for rigitrodes (Discharge Electrode)
Rapping arrangement for Collecting plate
 Rapper coil

Rapper plunger

Rapper rod

Hyplon boot

Rapper studs

Boot mounting
assembly
Earthing clamp

Rapper coil
 Rapping arrangement for Collecting
plate (Internal )
Spreader bar

Rapper rod
Positioner

Rapper rod

Anvil
 Insulator rod

Rapper rod Coupling

Rapper rod
Spring
retainer
Support spring

Insulator cover

Support Insulator

Gaskets
Insulator heater

Sliding base

Rapping arrangement for Discharge Electrode

 Rapper coil

Rapper Plunger

Anvil

Insulator rod/shaft
insulator

Hyplon boot

Rapping arrangement for Rigitrode Assembly

Door Interlock System

 The ESP is equipped with safety interlock

system to ensure the safety of the operating
personnel.

 The lock system is designed such that no

person can enter the ESP without isolating
the field from the High voltage system.
Door Interlock System
 G and D type on TR set
D type on access door

Interlock box

D type on TRCC
Safety Door Interlock System
 Accessories for ESP

 The ESP is equipped with the following accessories :-

– Insulator heaters- To warm up the support insulators. These heaters

are controlled by thermostat (trip at 90 Deg C)

– Hopper level switch:- to alarm in case of ash accumulation in the

hopper and tripped respective TR Set.

– Purge air blower :-To pressurize the pent house so that there is no
deposit on the inner surface of the support insulator.
Purge air Blower:-
 Interlocks in the ESP

 The following interlocking are provided for the TR sets for

the smooth and safe operation of the ESP. The TRCC for
the corresponding field will trip when any of the below
mentioned interlocks fails :-
– Door safety interlock
– Purge air blower trip (Common for all the fields)
– Hopper level high
– RAV interlock
DO NOT BYPASS ANY INTERLOCKS
OPERATION PROCEDURE

 Start up of ESP during COLD start up:-

– Insulator heaters should be kept ON 12 hours prior to
Plant light up.
– Switch ON the rapping system and the Ash handling
system - 02 hours prior to plant light up.
– Switch ON the Purge air blower ON one hour prior to
Plant light up.
– Once the Plant is steady and the flue gas
temperature at the ESP inlet is >150 degree C, Switch
ON the TRCC one by one .
OPERATION PROCEDURE
 ESP Shut OFF procedure:-
– When the flue gas temperature at the ESP
inlet go’s below or above deg.C,all the TRCCs
should be switched OFF immediately.
– All the other auxiliaries should remain ON .
 During Plant Shut OFF:-
– Switch OFF all the TRCCs immediately.
– Keep all other auxiliaries ON for another 02
hours.
DOs
1. Do operate the T/R sets in Auto mode only .
2. Do ensure that the hopper heaters and insulator heaters are
working for at least 12 hours before taking ESP on line.
3. Do use adequate headgear , eye and face protection and
respiration equipment wherever required while working in
and around ESP .
4. Do check that all grounding hooks are properly connected
to ground and that the braided copper wire upto earth
terminal is not broken, before entering into ESP to switch
off the T -R sets in case of tripping of ID fan.
DON'T s
1. Do not take the ESP on-line until the acid dew point
temperature reached. Ensure that the T/R sets are
Switched 'ON' only after attaining the dew point
temperature. The acid dew point temperature for varying
sulfur content in the fuel is as given in the chart below (if
applicable).
2. Do not allow access to ESP internals and power supplies to
any person who is not trained in ESP operation and
Maintenance.
3. Do not enter ESP without ensuring grounding of the T/R
sets and Electrode system with the help of grounding
Hooks.
4. Do not try to defeat the mechanical key interlock systems.
5. Do not duplicate keys of interlock system.
6. Do not enter ESP without carrying the extra interlock
key to avoid the situation of accidental closing of
access doors of ESP , when some persons are still
inside.
7. Do not set the intensity of emitting electrode rappers to a
value beyond 10 ft lb (Normal setting 5 ft-lb)
8. After maintenance or inspection of ESP internals do not
switch 'ON' T/R sets before making a head count to
ensure that all the personnel working within
ESP/penthouse have come out.
9. Do not run T/R sets in manual mode.
T roubleshooting Guide
SR. NO PROBLEM PROBABLE CAUSE REMEDY
1 T/R High V Full Hopper(s), dust build- Investigate for
oltage Short up between emitting and probable cause of
Circuit collecting short circuit, clear
electrode. and/or repair
Metallic debris left in ESP as required and
during check for any
shutdown, ground jumper damage
left on
2 T/R High V H.V . jumper cable from Connect jumper
oltages Open bushing to cable
Circuit bus section not connected
3 Rapper Open fuse(s) Check fuses
Control Open circuit breaker, open Investigate reason
Failure rapper , disconnected for breaker or
Condition: switch, de-energized starter switch being open,
Loss of power replace or
supply in repair as required
Rapper Refer microtapper
control controller
cabinet loss manual
4 Insulator Heater failure due to short
Heater F circuit or low resistance to
ailure ground
5 Hopper Dust 1. Hopper ash evacuation
Level High system orRAVmalfunction
2.Cold air leakage into
hopper
3.Dust blockage in hopper,
particularly at discharge
6 Hopper Wall Inoperative hopper heaters
Ash Buildup
Locate defective heater
element & replace
1.Check local panel to
identify the hopper
Investigate for system
failure
2.Check hopper access door
for
proper closure & seal
3.Clean blockage or buildup
Investigate for heater failure
 THANK YOU

M.Mohanraj
Mobile: +91 90425 60640
Mail ID: tmsmohanraj@gmail.com