Electrostatic Precipitator

This presentation is made for understanding the working of ESP in power plant. and also what are equipment are used with technical data.

1. “Electrostatic Precipitator ESP”
Stage II, 2*660MW
MPPGCL, Khandwa
PRESENTED BY:
VINAY VISHWAKARMA
G.E.T.

2. Electrostatic Precipitator

3. Introduction
Adevicethatremovessuspendeddustparticlesfromagasorexhaustbyapplyingahigh-voltage
electrostaticchargeandcollectingtheparticlesonchargedplates.
Electrostaticprecipitationisamethodofdustcollectionthatuseselectrostaticforces,andconsistsof
dischargewires(negativeplates)andcollectingplates.(positiveplates)
Ahighvoltageisappliedtothedischargewirestoformanelectricalfieldbetweenthewiresandthe
collectingplates,andalsoionizestheairaroundthedischargewirestosupplyions.
Whenairthatcontainsanaerosol(dust,mist)flowsbetweenthecollectingplatesandthedischargewires,
theaerosolparticlesintheairarechargedbytheions.
TheCoulombforcecausedbytheelectricfieldcausesthechargedparticlestobecollectedonthe
collectingplates,andthegasispurified.

4. Basic Diagram of ESP

5. Location of ESP
Step Up
Transformer
TG Area Boiler ESP Chimney

6. Purpose of Installing
Thefluegasesproducedduetocombustionofsolidpulverizedfuelinthefurnacecontainplentyofdust
particles.
Whenachimneyreleasesthesefluegasesintheatmospherewithoutfilteringthesedustparticles,the
atmospheremaygetpolluted.
Hence,thesedustparticlesneedtoberemovedfromthefluegasesasmuchaspossiblebeforetheseflue
gasesgetdischargedtotheatmosphere.
Byremovingthedustparticlesfromfluegases,wecancontroltheairpollution.
Electrostaticprecipitatordoesthisworkforafurnacesystem.
Weinstallthisdeviceinthewayoffluegasesfromthefurnacetothechimneysothatthedevicecanfilter
thefluegasesbeforetheyenterthechimney.

7. Working
Theworkingprincipleoftheelectrostaticprecipitatorisquitesimple.Ithastwosetsofelectrodesoneis
positive,andanotherisnegative.Thenegativeelectrodesareintheformofrodorwiremesh.Positive
electrodesareintheformofplates.
Thepositiveplatesandnegativeelectrodesareplacedverticallyintheelectrostaticprecipitatoralternatively
oneafteranother.
ThenegativeelectrodesareconnectedtoanegativeterminalofhighvoltageDCsource,andpositiveplates
areconnectedtothepositiveterminaloftheDCsource.ThepositiveterminaloftheDCsourcemaybe
groundedtogetstrongernegativityinthenegativeelectrodes.
ThedistancebetweeneachnegativeelectrodeandpositiveplateandtheDCvoltageappliedacrossthemare
soadjustedthatthevoltagegradientbetweeneachnegativeelectrodeandadjacentpositiveplatebecomes
quitehightoionizethemediumbetweenthese.

8. To be continued…

9. To be continued…

10. To be continued…

11. Parts of ESP
1.Collecting Electrodes
2.Discharge Electrodes
3.Transformer Rectifier Set (TR Set)
4.Support Insulator Heater (SIH)
5.Rapper Coil (CR, DR, GD)
6.Temperature Transmitter
7.Pressure Transmitter
8.Opacity Monitor/ Blower
9.Resistance Temperature Detector
10.Hopper Area
11.Hopper Heater (26 Module)
12.Low Level -Dust Level Indicator
13.High Level -Dust Level Indicator
14.Electronic Unit
15.Thermostat

12. Trestle

13. Control Room -PMCC
1.Source/ Power Transformer
2.Power cum Motor Control Centre (PMCC)
3.TR Panel Room

14. SOURCE/ POWERTRANSFORMER

15. Source/ Power Transformer
This Power transformer is a step down type transformer which fed power to TR Set, PMCC
Panel and then to all load which is used in ESPs.
Voltage level: 11KV to 440V.
Such load are Hopper Heater, Support Insulator Heater, Dust Level Indicator, Rapper Coil,
Hoist, Opacity Blower, Lighting Induced Draught Fan and all machine which is working for ID
fan.
Power is directly fed to PMCC panel through busbar duct.

17. Name Plate Detail of Power
Transformer

18. POWER CUM MOTOR CONTROL CENTRE

19. Power cum Motor Control Centre
Itisanassemblyfromwherethepowerofanequipmentormachineisbeingcontrolledwhichisincenter
location.
ItconsistsofBreaker,Busbar,Fuse,IndicationLight,Relay,Contactor,ProtectionTransformermetering
equipment.
HerePanelused440Vtofeedload.
ItcontainsTRPanelfeeder,SIHfeeder,HopperHeaterfeeder,OpacityBlowerPowerSupply,Rapper
PanelPowerSupply,DLIfeeder,IDfanfeederetc.
ItalsohavinganarrangementofBus-couplertotransferpowerfromonesidetoanothertofeedload
duringmaintenanceofPowerTransformer.

20. PMCC Testing
BeforechargingaPMCCPanelsometesthavebeenfollowedbyvendor/client.Theyareasfollows:
1.MeggerTestonBusbar:BythistestweareconfirmingthatourBusbarisshort/open.Ifshortthenthe
meggerreads0ΩsandifitisopenthenmeggerreadsaboveGΩ.
2.HiPotTestonBusbar(HighPotential):Bythistestweareinjecting2KV(4-5timesofratedvoltage)to
BusbarbythehelpofStep-upTransformerandtakesthevalueofcurrentreading.Ifclampmeterreads
below50mAthenthebusbarisinhealthycondition.ItisalsoknownasDielectricWithstandtest.
3.RelayTesting:Inthistestwecheckthatrelayisworkingproperlyornot.(UnderVoltageTrip,Over
CurrentTrip,OverVoltageTrip,DifferentialProtection).
4.ContactResistanceMeter(CRM):Thistestisespeciallyimportantforcontactsthatcarrylargeamounts
ofcurrent(switchgearbusbars)becausehighercontactresistanceleadtolowercurrentcarryingcapacityand
higherlosses.Ductortestingisusuallyperformedusingamicro/milli-ohmmeterorlowohmmeter.
#To ensure the busbars joints are givingminimumreading.
#Gradually increase the injected DC current to a specified current (e.g. 100A, 200A), then take the
micro-ohms reading.

21. To be continued…
Contact
CRM Test
Breaker AssemblyDistance between two Busbar
Megger & Hi-Pot Test CRM Test

22. Feeder given on PMCC Panel
S. No FEEDER CAPACITY FUNCTION
1. To TR panel(Pass A) 400A Togive supply to Transformer Rectifier Set for charging field/ electrode.
2. To SIHJB 25.5KW To give supply to supportinsulator heater for maintain the temperature of insulator.
3. To Electrical Hoist Motor Feeder63A To give supply tohoist for loading & unloading of machine.
4. Power Supply to Rapper Panel 63A To give supply to rapper panel to runrapping system.
5. To hopper heater JB 23KW To give supply to hopper heater JB to increase the temperature of ash/ dust.
6. To ID fan MCC 250A To run ID fan for takingout minute particles in the air through chimney.
7. Rawpower supply to EPMS 63A To run PLC for automation of an equipment locatedon remote area from control room.
8. Blower for opacity monitor 0.55KW To run opacityblower/ motor
9. 9:10A MCB O/G(7w+2S) 9:10A To give supply toDLI to operate.
10. LINE-APT & Auxiliary
Equipment
50VA
11. Incomer –I 4000A
12. To Welding Receptacles for SWR.
Room
63A To give supply fordoing welding in location site.
13. BUS-APT & Auxiliary Equipment50VA
14. Spare 23KW For future use
15. Spare 63A For futureuse

23. TR Panel Feeder
1.TR Panel feeder is only used to transfer power to
TR Panel from PMCC Panel.
2.It is used when user want maintenance in TR
Panel.

24. Hopper Heater Feeder
1.Thehopperheaterisdesignedtopreheatthehoppertopreventmoisturecondensatefrom
collectingashinitduringstartupconditions.
2.Inaddition,theymaintainthehopperandflyashattemperatures(50⁰Cto150⁰C)abovetheflue
gasaciddewpointduringnormaloperatingconditions.

25. To be continued…

26. Circuit Diagram
26 Heater Module per hopper

27. Dust/ Ash Level Indicator (DLI/ ALI)
1.DLI is a electronic device which is used to detect the ash level in hopper to protect the hopper from
overloading.
2.A change of Level of material in the hopper causes a change in dielectric which in turn causes a change
in admittance of this imperfect capacitor. An accurate measurement of this change affords an indirect
measure of the level of material in the tank.

28. Support Insulator Heater Feeder
#Cylindricalorconicalsupportinsulatorsareusedforthe
suspensionofthecollectingelectrodesandtoprovide
insulationtotheESPhousing.

29. To be continued…

30. Rapper Panel & Rapper JB
1.Rappersareusedtotransmitstrongshearingforcestocollectingplatesinordertoreleasedepositeddust
particles.
2.Rappingistheprocessbywhichelectrodesandparticlesarebrokenapartbyvibrationsfromtherappers.
Oftenusedinelectrostaticprecipitators,rappersrelapsethecakedondustlayerwhichthendescendsintoa
hopper.
3.Number,size,andfrequencyoftherappersvaryfromsystemtosystembaseduponthespecific
characteristicsofthedustbeingcollected.

31. To be continued…

32. Cross-Sectional View of ESP
Ground Discharge Rapper
Funnel
Hopper
Gas Distribution System
Collecting Electrode
Support Insulator
Discharge Electrode
Rapping System
HV Transformer DC

33. Temperature Transmitter & Pressure
Transmitter
1. Apressure transducer, often called apressure transmitter, is a transducer that converts pressure into an
analog electrical signal. Although there are various types of pressure transducers, one of the most common is
the strain-gauge base transducer.
2. A temperature transmitter is an electrical instrument that interfaces a temperature sensor (e.g.
thermocouple, RTD, or thermistor) to a measurement or control device (e.g. PLC, DCS, PC, loop controller,
data logger, display, recorder, etc.).
3. An RTD or Resistance Temperature Detector is a passive circuit element whose resistance increases with
increasing temperature in a predictable manner.2

34. Pressure Transmitter & RTD

35. Opacity Monitor (OPM)

36. Electrical Hoist

37. TRANSFORMER RECTIFIER PANEL

38. TR PANEL ROOM

39. Name Plate on TR panel
ELECTRONIC CONTROLLER
FOR H.V.RECTIFIER FOR ELECTROSTATIC PRECIPITATOR
MODEL ADOR CORONA
SERIAL NO. 15701-01-07-2018
CUSTOMER M/S L&T
PROJECT NO. 6678
ORDER REFERENCE NO. 01/1100/01334
RATED INPUT VOLTAGE 415 VAC 50 Hz
RATEDINPUT CURRENT 302 AMPS
RATED OUTPUTVOLTAGE 95 KV (P) DC
RATED OUTPUT CURRENT 1300 mADC
DATE OF MANUFACTURE JULY-2016
MADEIN INDIA
ADOR POWERTRON LIMITED. PUNE -411019 0551-2000-16-35/3

40. Need of TR Panel
ThemainpurposeofinstallingTRPanelbeforeTRSetisasfollows:
1.Builtincurrentlimitingreactortoprotecttheelectricalsystemfromfrequentshortcircuitsinthefield.
2.Extraheavydutydesignsuitablefor95to120KVpeakvoltage,basedonapplicationrequirement.

41. Inside TR Panel
Meter KV, V, mA, A
Meter Calibration card
Display
Emergency Stop Button
Local/ Remote Button
SCR
Mechanical Interlock
CTs
TB 4
HRC Fuse 415V
Main Contactor
Fuse
DOC IV-Controller
Relay
Control Transformer
Auxiliary Contactor
Earthing Busbar
MCBs for Controller
Lamp Holder
Manual handle for ON/ OFF

42. Testing of a TR Panel/ Transformer
BeforechargingtheTransformerfirstly,wedosometestonTRPanelandH.V.Transformer.Thetest
areasfollows:
1.CableContinuityandMeggerValueshouldnotbelessthan1GΩ.(MeggerVoltage5KV)
2.TransformerPrimaryandSecondarywindingmeggertest.Itshouldalsonotlessthan1GΩ.
3.TRPaneltesti.e.checkingthatpanelgivingratedoutputvoltage.Ifnotthencontrollermaybe
faulty.Thistestiscalled“LampLoadTest”.(ControllershouldbeinManualMode)
4.Ifcontrollerhealthythenwedo“OpenCircuitTest”onaTransformerandobservetheinputand
outputvoltage.(Ratedinputvoltageisapplied)
5.Thenwedo“ShortCircuitTest”onaTransformerandobservetheinputandoutputcurrent.
(Ratedinputcurrentisapplied)
6.Thenfinallywechargethetransformerandputunderobservation.

43. Problem & Troubleshooting on TR Panel
S. No PROBLEM TROUBLESHOOTING REMARKS
1. INPUT VOLTAGENOT INCREASING
2. INPUT CURRENT NOT INCREASING
3. OUTPUTVOLTAGE NOT INCREASING
4. OUTPUTCURRENT NOT INCREASING
5. INSTANTANEOUSLY CURRENT
INCREASING
SCR UNBALANCED
6. EXTERNAL ALARM 1 DLI HIGH LEVEL H1
7. EXTERNAL ALARM 2 DLI HIGH LEVEL H2
8. EXTERNAL ALARM 3
9. EXTERNAL ALARM 4
10. MAINCONTACTOR NOT PICK-UP

44. Transformer Rectifier Set (TR Set)
1.TheTRisastatictransformerwhichstepupthevoltagefrom440Vto95KVandthenconverted
theA.C.voltageintoD.C.voltagewiththehelpofBridgeThyristor.
2.ThenegativeterminaloftransformeriscarriedbyBusbar(coppertube)tothefieldinto
dischargeelectrodewiththehelpofsupportinsulator.
3.Thepositiveterminalofoutputvoltageisgiventocollectingelectrode.
4.Boththeelectrodesarealwaysinopencondition.Sotherewillbeinduceelectricfieldbetween
theelectrode.
5.Thatelectricfieldenergizetheashparticlesandattractedbythecollectingelectrode(positive
terminal).
6.Thenaftersometimerappingsystemworks,whichremovesthedustparticlesfromelectrodeand
getcollectedtothehopper.

45. Transformer Rectifier Set

46. P.L.C. AND S.C.A.D.A.
Programmable Logical
Controller
Supervisory Control And Data
Acquisition

47. Programmable Logical Controller (PLC)
Programmable logic controller
Its a hardware, which is directly in
contact with field instruments. It
works according to the logic
stored in PLC Memory.
It uses a language called “Relay Ladder Logic”.
Positive Logic (most PLCs follow this convention)
True = logic 1 = input energized.
False = logic 0 = input NOT energized

49. Supervisory Control And Data Acquisition
(SCADA)
1.Itsasoftware,whichshowstheoutputandfeedbackinVisualmanner,
thatPLCcan'tdo.
2.AprogrammerdesigntheanimationasperPLCprogrammingand
fieldequipmentposition,thenmakecommunicationbetweenSCADA
andPLC.
3.AftersuccessfulcommunicationbetweenSCADAandPLCwecan
VisualizetheoperationwhichishappeninfieldfromControlRoom.

50. Some Pictures of SCADA screen

58. EARTHING

59. Importance of Earthing
OverloadProtection–Inscenarioswhereexcessivepowersurgeoccurs,agroundedsystem
helpsimmensely.Thissimpleformofsurgeprotectioncaninstantlysaveyourelectricalmachine
anddevicesfromgettingfriedbyexcessiveelectricalpower,savingyourdataaswellas
equipment.
VoltageStabilization–Whenitcomestocalculatingtherightamountofpowertobe
distributedbetweenvoltagesources,theearthprovidesthatuniversalstandardpointofreference.
Earthingtakestheguessworkoutofvoltagestabilization,helpingtoensurethatnocircuits
overloadorblowup.
Damage,Injury&DeathPrevention–Blownfusesoratrippedcircuitbreakersarefarmore
welcomethanelectricalfiresorshocks,whichcanposeserioussafetyhazardstopeopleand
property.Essentially,groundingprotectsagainstequipment,propertyanddataloss,aswellas
injuriesandfatalities.

60. CABLE DATASHEET

61. S.No. EQUIPMENT SIZE CABLE TYPE
1. TRANSFORMER RECTIFIER 2C-300 SQ.MM ARMOURED
2. RAPPER PANEL 3C-25 SQ.MM ARMOURED
3. RAPPER COIL 2C-2.5 SQ.MM ARMOURED
4. OPACITY BLOWER 3C-6 SQ.MM ARMOURED
5. SUPPORT INSULATOR HEATER 3C-50 SQ.MM ARMOURED
6. HOPPER HEATER 3C-35 SQ.MM ARMOURED
7. DUST LEVEL INDICATOR 2C-6 SQ.MM ARMOURED
8. HOPPER HEATER LOOPING 3C-10 SQ.MM ARMOURED
9. WELDING RECEPTICLES 3.5C-35 SQ.MM ARMOURED
10. EPMS/ PLC 3C-6 SQ.MM ARMOURED
11. ELECTRICAL HOIST 3C-16 SQ.MM ARMOURED
12. CONTROL CABLE 27C, 7C,5C, 3C, 2C-2.5 SQ.MMARMOURED
13.
14.
PAIR CABLE
COMMUNICATION CABLE
16P, 8P, 4P, 2P-0.5 SQ.MM
2P-0.35 SQ.MM
SCREENED
SCREENED
* Above cable are used for this plant only, where load will be different then cable size are also changed.

62. THANK YOU
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