Rei Vol Vii

CETHAR VE SSE LS LIMITED
M/s. REI AGRO LIMITED. 2 X 36 MW CAPTIVE POWER PLANT BOILERS (BG059 & BG060)
TABLE OF CONTENTS
SL. NO.
01 02 03 04 05 06 07
DESCRIPTION
ESP PROJECT DESCRIPTION ESP TECHNICAL SPECIFICATION ESP WORKING PRINCIPLE ESP COMPONENT DESCRIPTION ESP ERECTION AN OVER VIEW ESP PERFORMANCE TEST PREPARATORY WORK ESP TROUBLE SHOOTING
PAGE NO. 002 003 008 015 020 024 028
08
SUB VENDORS MANUALS

MICRO TAPPER CONTROL PANEL DUST LEVEL INDICATOR TRANSFORMER RECTIFER UNIT RAPPER DISTRIBUTION PANEL ELECTRODES SPIKE ROD EARTH DISCHARGE ROD PURGE AIR FILTER MECHANICAL SAFETY INTERLOCK HEATERS
035 059 076 142 143 144 145 146 147 155 157
09
ESP MCC DRAWINGS
CVL ELECTROSTATIC PRECIPITATORS
ESP PROJECT DESCRIPTION

NAME OF CUSTOMER : M/s. REI AGRO LIMITED.
SITE ADDRESS
KUTCH, GUJARAT.
WORK ORDER NUMBER
M/B/G/059 & M/B/G/060.
BOILER NUMBER
BG059 & BG060
TYPE OF BOILER
SINGLE DRUM WATER TUBE BOILER (AFBC)
MAKE OF BOILER
CVL
BOILER CAPACITY
80 TPH
STEAM PRESSURE
86 Ksc (a)
STEAM TEMPERATURE
520 5C
NUMBER OF BOILER
TWO
NUMBER OF ESP
TWO
O & M MANUAL FOR ESP
ESP TECHNICAL SPECIFICATION

SL.NO. 1.0 1.1 1.2 1.3 1.4 2.0 2.1 2.2 2.3 2.4 2.5 2.6 2.7 2.8 2.9 2.10 2.11 2.12 3.0 3.1 3.2 3.3 3.4 ITEMS UNITS VALUES
GENERAL INFORMATION - BOILER Boiler Type Boiler Capacity Steam Pressure Steam Temperature Manufacturer Fuel Flow Flue gas temperature Inlet Dust Concentration Outlet Dust Concentration ESP Type Overall Dimension (L x W x H) Column To Column Dimension Per Field Number Of Electric Field In Series Total Active Treatment Length Per Stream Treatment Time COLLECTING ELECTRODES Type Material Electrode Thickness Clear Distance b/w Collecting Electrode Plates No of gas Passes / Stream mm mm Modified G profile IS 513 1.25 400 m m Nos m s m3 / s C
gm/ Nm3 mg/ Nm3
AFBC TPH Ksc(a) C 80 86 520 5 CVL Imported Coal 35.09 160 4.94 100 70% K. Lignite+ 30% Imp. Coal 39.4 160 28 100
GENERAL INFORMATION ESP
Horizontal flow dry type Refer G.A. drawing Refer G.A. drawing 3 10.8 25.71
3.5
Nos
3.6 3.7 3.8 3.9 3.10 3.11 3.12 3.13 4.0 4.1 4.2 4.3
Active Length per Electrode Cross Sectional Area of Each Passage Active Height Per Electrode Specific Collecting Area Total Collecting Area Total Number Of Electrodes Number Of Electrodes Per Stream Aspect Ratio (L/H) DISCHARGE ELECTRODES Type Material Total Number Of Electrodes Per Gas Path Distance Between Effective Discharge Electrode In Direction Of Gas Passage Total Number Of Electrodes Tensioning Arrangement
BUS SECTION
mm m2 mm m2/m3/ s m2 Nos Nos
450 4.0 10000 129.27 4536 528 528 1.08 Spike Electrode IS 1239
Nos
24
4.4 4.5 4.6 5.0 5.1 5.2 5.3 5.4 5.5 6.0 6.1 6.2 6.3 6.4 6.5
Mm Nos
457.5 504 Bolt at both end
Total Numbers Total Number Per Stream Number Of Bus Sections Ht Voltage Number of Sections Lost If One Transformer Is Out of Service Type Accessibility Total Number of Rapper Per Unit Maximum No. of Electrodes Rapped By a Rapper At One Time Time Interval Between Raps of Same Rapper
Nos Nos Nos Kv Nos
3 3 3 120 One
RAPPING SYSTEM COLLECTING ELECTRODE
EMIGI coil type Outer roof Nos Nos Sec 33 16 Field Adjustable
6.6 6.6.1 6.6.2 6.6.3 6.6.4 7.0 7.1 7.2 7.3 7.4 8.0 8.1 8.2 8.3 8.4 8.5 9.0 9.1 9.2 9.3 10.0 10.1 10.2 10.3 10.4 10.4.1 10.4.2 10.4.3 10.4.4
RAPPER CONTROLLER COLLECTING Type Timing Sequence Protection Indicating Instruments

RAPPING SYSTEM EMITTING ELECTRODE
Microprocessor based programmer Programmable IP 54 Provided EMIGI coil type Outer roof Nos Sec 12 Field Adjustable
Type Accessibility Total Number Of Rapper Per Unit Time Interval Between Raps Of Same Rapper
HIGH TENSION SUPPORT INSULATOR
Type Material Leakage Distance Maximum Flash Over Location

SUPPORT INSULATOR ELECTRIC HEATER
Cylindrical Porcelain mm Kv 610 170 (Dry) Pent house KW 0.75 Thermostatic 1 Nos 3 1 Roof mounted Step up double wound Class A Deg C KV , AC 50 52
Rating Control Number Per Insulator Compartment

TRANSFORMER RECTIFIER UNIT
Total Numbers Per Stream Number Per Field Mounting Type And Location
TRANSFORMER
Type Of Transformer Class Of Insulation Temperature Rise Over Ambient Class Of Bushing
10.4.5 A B C 10.4.6 10.5 10.5.1 10.5.2 10.5.3 10.6 10.6.1 10.6.2 10.6.3 10.6.4 10.6.5 10.6.6 10.6.7 10.6.8 10.6.9 10.6.10 10.6.12 11.0 11.1 11.2 11.3 11.4
Rating Of Each Set Input Power Output Voltage Output Current Volume Of Oil
RECTIFIERS
KVA
KV (Peak)
49.50 120 450 SCR Bridge Full-Wave
mA (Mean) 600
Litres
Type Hall-Wave / Full-Wave Rating - Each

TRANSFORMER RECTIFIER CONTROL UNIT
KVA
50
Number Offered Type Of Cabinet Voltage Control Arc Suppression Protection Instrumentation Provided As Required Signal Circuit mm X Cabinet Dimension (L x W x H) Design Ambient Temperature Power Supply V, Phase, Hz Earthing and Shielding
ESP CASING
3 Free standing Provided Provided IP 54 Yes Provided mm X mm Deg C 50 415 / 1 / 50 Provided mm mmWg 4 -250 Welded IS 2062 GR. A 700 X 650 X 2000
Plate Thickness Design Pressure Construction Type Material
12.0 12.1 12.2 12.3 12.4 12.5 12.6 12.6.1 12.6.2 12.7 13.0 13.1 13.2 13.3 14.0 14.1 14.2 14.3 14.4
DUST HOPPER
Total Number Total Hopper Storage Capacity Per Field Plate Thickness Material Hopper Valley Angle
FLANGE OUTLET TO ATTACH TO ASH HANDLING SYSTEM
3 M3 mm Deg 35.82 5 IS 2062 GR. A 57
Type Size Height Above The Ground Level

ASH HOPPER ELECTRICAL HEATERS
Flanged mm mm 400 x 400 3500
Rating Number Per Hopper Control

PERFORATED GAS SCREENS
KW Nos
1 3 Thermostat Perforated sheets IS 1079
Type Material Thickness Location mm
2 3 @ inlet & 1 @ outlet
ESP WORKING PRINCIPLE

INTRODUCTION: -
Now a day the suspended particulate matter from the industrial exhaust is the major pollutant of our atmosphere. The smoke will be having solid as well as fluid
suspended particles. In most of the industrial processes these suspended particles are the residues of those processes and it has to be removed before they are being exhausted into the atmosphere. In some industrial processes, this suspended particle may be useful product or reusable products to be collected to make the process more profitable. An earlier stage ESP had been used for this purpose only. Later on it has been found as a way of most efficient dust collecting equipment for many of the industrial applications.
PRINCIPLE: -
Electrostatic precipitator is basically electrical equipment in which the dust has been removed from the flue gas by means of electrical discharge and the removed dust is collected by means of mechanical rapping system. precipitator will be of the following four phases The operation of electrostatic
Ionization of flue gas by high voltage discharge Charging of dust particles Migration and collecting of dust particles Removal of collected dust
WORKING: -
In order to obtain gas ionization it is necessary to exceed, at least locally, the electrical breakdown strength of the gas. It is called corona. Sparking is essentially an
advanced stage of corona in which complete break down of the gas occurs. Precipitators are usually operated at the highest voltage practicable without sparking, since this increases both the particle charge and the electrical precipitating field.
Corona discharge is accompanied by a relatively small flow of electric current. Sparking usually involves a considerably larger flow of current, which cannot be tolerated except for occasional periods of a fraction of a second duration, and then only when suitable electrical controls are provided to limit the current.
However, when suitable controls are provided, precipitators have been operated continuously with a small amount of sparking to ensure that the voltage is in the correct range to ensure corona. Besides disruptive effects on the electrical
equipments and electrodes, sparking will result in low collection efficiency because of reduction in applied voltage, re-dispersion of collected dust, and current channeling.
In the electrostatic precipitator, the dust laden flue gas is passed through the passages between the collecting and emitting electrodes. The emitting electrode is either spring or spikes welded to ERW tubes at regular pitch and collecting electrodes is of curtain like plates hung from top. A transformer rectifier set will feed a very high DC voltage to the emitting electrodes whereas the collecting plates are earthed. This high voltage emitting system ionizes the flue gas stream and form positive, negative ion cloud inside the electrostatic precipitator. This is called as the corona discharge or corona formation.
Once this cloud of charge is produced it will start charging the dust particle to its saturation level. The charged dust particles will be pulled towards the earthed
collecting electrode plates and get deposited over it. The movement of dust particles towards collecting electrodes will be opposed by viscous drag, collision of dust particles etc., and the resultant velocity with which the particle move towards the electrode is known as migration velocity or drift velocity.
As soon as the dust particles get precipitated over the collecting panels, they get discharged as the panels are earthed. The collected dust will be removed by the rapping mechanism at suitable preset timings.
ADVANTAGES OF ESP: -
Electrostatic precipitators have gained its popularity over other dust collecting equipments because of the following advantages Low pressure drop Higher collection efficiency Less sensitive for temperature variations Suitable for any type of dust Lower maintenance and runtime cost
PARAMETERS AFFECTING ESP PERFORMANCE: -
Electrostatic precipitators are usually designed for a set of inlet flue gas conditions. Variations in one or many of these parameters may lead to poor collection efficiency in electrostatic precipitator. Parameters influencing the performance of electrostatic precipitator are
Resistivity of dust particles Flue gas temperature at ESP inlet Flue gas volume flow rate through ESP Flue gas composition Flue gas velocity with in ESP Inlet dust concentration Dust particle size distribution Gas distribution inside ESP Rapping frequency
RESISTIVITY OF DUST PARTICLE: -
Resistivity is an electrical characteristics based on which the charging capacity of a dust particle at the given charging condition can be determined. Resistivity depends on the composition and morphology of the dust particles.
The problem due to high resistive dust particles is the back corona formation. Usually while operation there will be a voltage drop across the dust layer collected over the collecting plates. If the resistivity of dust layer is very high this voltage drop will
increase and it may be sufficient to produce sparking between collecting and emitting electrodes. In order to avoid this back corona effect the operating voltage and current of the precipitator to be reduce thereby reducing the performance of ESP. The low resistivity dust creates the problem of re-entrainment. If the resistivity of dust is very low then the particles will discharge rapidly as soon as collected over the collecting panels. Hence they are nowhere electrostatically pinned with collecting
electrodes and can be easily swept along with flue gas. Sometimes the particles will acquire positive charge from the collecting panel and get repelled. The problem of low resistivity mainly occurs with precipitators operating at low temperatures and handling ash from high sulphur coal.
FLUE GAS TEMPERATURE AT ESP INLET: -
The variation of resistivity of flue gas with temperature doesnt have a greater impact on the performance of ESP if the variation is minor. On the other hand the viscosity of flue gas increases with increasing temperature that imparts more drag on dust particles. The performance of electrostatic precipitator is highly influenced by increase in flue gas temperature. The raise in temperature will decrease the electrical property of flue gas i.e., the resistivity of flue gas will decrease with increasing temperature. This high resistivity of dust will lead to back corona effected thereby bringing down the operating voltage to reduce sparking. This plays a vital role in reducing the ESP performance at elevated temperatures. The above two phenomenon will significantly reduce the effective migration of dust particles thereby affecting the overall performance of the precipitator. This is the reason why an ESP designed for a
specific flue gas temperature may not perform satisfactorily at higher temperatures.
The strength of the mechanical components especially insulators will be reduced when the ESP is operated at a higher temperature than the designed value or if there is frequent variation of flue gas temperature over a wide range.
The lower operating temperature will aid the performance of ESP as the resistivity of dust particles reduce with decreasing temperature. The lower operating temperature will create problem if it falls below the acid dew point temperature leading to corrosion of structural and mechanical components of ESP.
FLUE GAS VOLUME FLOW RATE THROUGH ESP: -
Based on the flue gas composition the amount of collection area required for conditioning the gas to the required dust level will vary. The amount of collection area required per cubic meter of flue gas is called as the specific collecting area (SCA). The total collection area (TCA) of the precipitator will be arrived by multiplying the SCA with the design flue gas flow rate. Increase in gas volume will therefore
decrease the SCA required for the flue gas and thus reducing the performance of electrostatic precipitator.
FLUE GAS COMPOSITION: -
The composition of flue gas plays a vital role in design as well as in the performance of ESP. The effect of some of the major composition of flue gas, which highly affects the performance of ESP, has been briefed below
PERCENTAGE OF MOISTURE IN FLUE GAS
The percentage of water vapour present in flue gas has a greater influence on the performance of ESP. The more percentage of water vapour will aid the performance of ESP by reducing the resistive nature of flue gas. If the ESP has been designed for a specific percentage of moisture in flue gas, then the performance of the ESP will deteriorate with decreasing moisture percentage. A maximum increase of 5% of
moisture in flue gas can improve the performance of ESP to certain limit.
PERCENTAGE OF SULPHUR OXIDES IN FLUE GAS
The free sulphur tri oxide formed during the combustion of fuels condenses with moisture on the surface of the particles and thus reduces the resistivity of dust particles.
In some cases larger portion of sulphur in fuel may form as calcium sulphate, which is highly resistive.
The formation of sulphur tri oxide may raise the sulphur dew point temperature thereby wetting the dust by the sulphuric acid formed. This makes the dust to get clogged into ESP and reducing the performance of ESP.
PERCENTAGE OF OXIDES OF SALTS IN FLUE GAS
The presence of oxides of salts like calcium and magnesium oxides will result in formation of dust layer over emitting electrodes and theyre by suppressing the corona formation. This reduces the performance of ESP.
PERCENTAGE OF ALKALI METALS IN FLUE GAS
The alkali metals like sodium and potassium present in the fuel forms alkali sulphates, which increases the moisture absorbing capacity of dust particles. collection rate will increase if the alkali metals are present in larger amount. Hence the
FLUE GAS VELOCITY WITHIN ESP: -
The flue gas should flow as a streamlined flow inside the ESP with an optimal velocity. Higher operating velocity will decrease the effective migration velocity as well as the carryover of collected dust particles along with flue gas. Lower operating velocity will lead to stagnation of flue gas at lower zones of ESP.
INLET DUST CONCENTRATION: -
The SCA provided is suitable for a particular amount of inlet dust load to achieve the required outlet emission. Hence if there is any drastic increase in the amount of inlet dust concentration the collection area provided will not be adequate to achieve the required outlet emission. The outlet emission will increase with respect to increasing inlet dust load for a given ESP.
DUST PARTICLE SIZE DISTRIBUTION: -
Larger sized dust particles will have more area to collect charges and get charged quickly; hence they migrate faster towards the collecting plates thereby increasing the collection efficiency. Migration velocity is proportional to diameter
GAS DISTRIBUTION INSIDE ESP: -
The flue gas entering into the precipitator should be evenly distributed over the entire cross sectional area to achieve maximum performance. It avoid the over loading of certain zones and non usage of certain electrode zones. Practically it is not possible to attain perfect distribution of flue gas over the entire area especially at the lower and upper extremities of electrodes. The variation of flue gas in these areas has to be minimized and maintained within a permissible limit to achieve better performance.
RAPPING FREQUENCY: -
The collected dust particles are to be removed in certain intervals by means of rapping mechanisms. The rapping frequency should be set with respect to the type and
amount of dust collected in the precipitator. Higher rapping frequency will lead to reentrainment of dust particles into the flue gas stream. Lower rapping frequency will lead to accumulation of thick layer of dust over the collecting plates thereby increasing the sparking between electrodes. The lower rapping frequency will also lead to heavy puffing of dust by re-entrainment while rapping. Hence a dust layer of sufficient
thickness should be allowed to form so that while rapping the layer breaks into agglomerate masses, sufficiently large to fall into hopper before being carried out by the gas stream. The rapping frequency can be individually controlled for each field based on the dust laden to the field.
ESP COMPONENT DESCRIPTION

The success of any system depends on proper design, selection of material and method for construction and also the design of associated systems. This section has been deputed to provide a general idea about the constructional features of CVL ESPs. The knowledge about the various components involved in a system will help the end user to know the system in detail and operate it in a more efficient way. This helps in sorting out the possible failure of system during operation and also easy for maintenance. As mentioned earlier the precipitator is made out of several bought out and shop made items. The major bought out item involved are the electrodes both collecting and emitting, insulators and transformer rectifier set.
COLLECTING ELECTRODES
The collecting electrode panels are usually 445 mm wide and 1.25 mm thick mild steel sheet made by cold rolling process. The profile of collecting electrodes is
aerodynamically designed for higher stiffness and to minimize re-entrainment of dust particles along with the fast moving flue gas. The collecting electrodes are also
designed to reduce sparks to sharp edges. The collecting electrode panels are bolted at both top and bottom to top and bottom tadpoles. The top tadpole is in turn rested on floating channel suspended from casing top girders. This type of construction enables the complete distribution of rapping force over entire area of panel. The bottom tadpoles are aligned using locking arrangements to maintain the electrical clearance with the emitting system during operation.
EMITTING ELECTRODES
The emitting electrode is a spike type of electrode consists of ERW tube on which copper coated spikes are welded at regular pitch in staggered manner to achieve uniform discharge throughout the entire length and width of collecting electrode. Usually one number of spike rod will be hung at the center per collecting electrode. The rigid construction of spike rod will reduce misalignment of electrodes during erection as well as during operation. Further these electrodes are easy to handle, install and to maintain.
SLIDING BEARING SUPPORTS
The ESP casing is supported over high efficient sliding bearings, which are taking care of casing thermal expansions. Three types of bearings are normally used called fixed, mono-axial and bi-axial bearings. The bearings have been designed for various loads such as vertical dead loads, vertical and horizontal loads due to wind and seismic. The bearing top plate to be bolted with casing column base plate and the bearing bottom plate to be welded or placed in races provided in supporting structure bearing plate.
T/ R SET WITH CONTROLLER
As the dust laden flue gas passes through the collecting electrodes and discharge electrode, the ESP can be considered as a capacitance having variable dielectric strength. The dielectric strength varies due to changing parameters of the flue gases.
The high voltage DC applied to the ESP has been continuously adjusted to minimize sparking across the discharge and collecting plates. The voltage controller in the transformer rectifier control cabinet senses the current feedback from the ESP and done the following functions.
It maintains the voltage across the ESP at the spark threshold level in all the conditions to achieve maximum efficiency.
During no sparking conditions, maximum power is made available across the ESP.
In case of spark, it brings down the voltage by preset value. The voltage is raised to spark threshold level if no further sparking is considered.
In case of arc it brings down the voltage to zero and blocks it for preset time. The voltage is restored to the preset value by fast ramp and then to the spark threshold level by slow ramp.
HIGH VOLTAGE SUPPORT INSULATORS
The entire emitting system is rested over high voltage porcelain cylindrical insulator that isolates the entire system from the casing, which is earthed. insulators have been designed for heavy compression loads. The support
The insulators are
located over ESP hot roof inside pressurized penthouse. Each insulator is provided with a coil type of heater to maintain the temperature of insulator slightly higher than ash condensation temperature. One number automatic on/off type of thermostat is provided to control the insulator heaters at required temperature level.
MECHANICAL SAFETY INTERLOCK SYSTEM
This system provides the personnel safety of person attending ESP. This system ensures that no person can enter into ESP unless all the Transformer Rectifier sets are de-energized and grounding switches of TR sets are in ground position.
HOPPER HEATERS
Continuous removal of collected ash from ESP ash hopper is essential for better as well as safe working of ESP. In order to maintain the free flow of ash through hopper discharge flange the bottom portion of ash hoppers are heated using coil type of heaters. This prevents ash build up in the hoppers. The heaters are thermostatically controlled to maintain the temperature up to a maximum of 230C.
HIGH LEVEL SWITCHES IN HOPPER
R.F. capacitance type level switches are provided in each hopper. The level switch operates when ash level inside the hopper rises and touches the level switch probe. The level switch gives signal to the audio visual alarm annunciator provided in the Auxiliary control panel to indicate high ash level in the hopper and trips the TR set. Even after tripping the TR set, the dust will continue to build up in hopper. Auxiliary contact of high hopper level relay will be provided in the Auxiliary control panel. If the high level alarm is persisting, it is recommended to stop the boiler after one-hour time delay. This prevents ash building up in the hoppers, which ultimately shorts the
emitting electrodes.
ESP CASING, HOPPERS, INLET AND OUTLET FUNNELS
Casing plays the important role in the construction of precipitator. It is made out of rigid welded construction consists of prefabricated columns, casing side and roof panels. The casing construction itself requires much higher time during erection. The casing has been designed for various loads as per IS standards and proper selection of column and stiffener members has been done to provide a rigid construction. The casing panels are fabricated either at shop floor or at site to closer tolerances. The casing is being erected with higher care, which minimizes electrode alignment problems. Pyramidal type of ash hoppers is provided for each field with sufficient storage hours and valley angles as per CVL standard design or to conform the customer requirement. The inlet and outlet funnels are designed for proper distribution of flue gas over the entire area of collecting surface.
COLLECTING ELECTRODE SUSPENSION
As explained earlier the collecting electrodes are bolted to top and bottom suspension frames (tadpoles), which are suspended, from floating channel. Each collecting
electrode panel is locked with adjacent collecting electrode panel by means of bolt at regular pitch through out the entire height to form a curtain like arrangement. The collecting electrode top and bottom frames are locked with suitable locking arrangements to maintain the electrical clearance with respect to emitting system. This firm fixing at top and bottom also provides sufficient rigidity and also uniform distribution of rapping force.
COLLECTING ELECTRODE RAPPING
The collecting electrode panels are provided with Electro Magnetic Impulse Gravity Impact (EMIGI) type of rapping system. The system consists of rapper induction coil. The sequence of operation is programmed in micro tapper panel, which generates an electrical pulse to the rapper distribution panel. The micro-taper panel is
microprocessor based programmable controller in which we can alter the rapping frequency and lift of plunger rod. On receiving pulse from micro-taper panel the diode
set in rapper distribution panel for the corresponding panel will power up the rapper by supplying a 220 V DC supply to the rapper coil. Once the rapper coil gets energized it lifts the plunger rod and drop it as soon as it is de-energized. This rapping mechanism provides efficient cleaning of collecting electrode panels. Usually one number rapper coil will be provided for two rows of collecting electrode panel. The rapping creates a vibration such that the dust cake dislodge from the collecting electrodes panels without getting broken. This avoids the re-entrainment of collected dust into the flue gas stream. The rapping frequency should be kept optimally which provides sufficient cleaning as well as reduce re-entrainment of collected dust.
DISCHARGE ELECTRODE SUSPENSION
The spike rods are bolted at top with the high voltage top suspension frame, which is suspended, from high voltage cylindrical support insulator and to the bottom suspension framework. The discharge electrode system is support with two or four support insulators per field based on size and weight of emitting assembly. The
discharge electrode system is exactly positioned between the rows of collecting electrode panels. The discharge electrode system is completely isolated from the collecting system and casing components for electrical clearance.
DISCHARGE ELECTRODE RAPPING
The discharge electrode panels are also provided with Electro Magnetic Impulse Gravity Impact (EMIGI) type of rapping system. The operation and control of these rappers will be similar to that of collecting electrode rapping. The rapper for emitting electrode will be located over the emitting electrode suspension rod. The suspension rod will be electrically isolated from the rapper coil by means of shaft insulator. The shaft insulator has been designed to provide suitable electrical isolation and also sufficient strength to transfer the rapping force of plunger to the emitting system.
ESP ERECTION AN OVERVIEW

INTRODUCTION:-
The purpose of this chapter is to provide overview of unloading and storage of critical components; erection, installation and alignment of internal components of CVL make Electrostatic precipitators.
UNLOADING AND STORAGE OF ESP COMPONENTS:-
The ESP consists of several bought out items as well as shop made and site fabricated items. reference. 1. 2. 3. 4. 5. 6. 7. 8. 9. Collecting Electrodes Spike Rods Sliding Bearing Supports Transformer Rectifier Set Support and Shaft Insulator Micro tapper Panel Rapper Distribution Panel Alarm Annunciation System & Hooter Hopper and Insulator Heaters with Thermostats The entire list of bought out items has been given below for
10. Dust Level Indicators 11. Auxiliary Control Panel 12. Mechanical Safety Interlocking Systems 13. Rapper Coils
As the above listed bought out items are dispatched directly to site from supplier end, proper facilities to be arranged at site for unloading, handling and storage of these items at site. Special care to be taken for storage and handling of components like Collecting Electrode, Spike Rods, Transformer Rectifier sets and Insulators. Below we have given some recommendations for unloading and handling of critical bought out items at site.
CVL ELECTROSTATIC PRECIPITATORS COLLECTING ELECTRODE PANELS: -
Before unloading the electrodes, an inspection to be carried out by the site engineer for any physical damage to the electrodes during transportation. The collecting
electrodes will be normally dispatched in steel cages in set of 30 electrodes per cage. The collecting electrode bundles should be unloaded carefully without allowing the plates to get bend while handling. The collecting electrode bundles should be stored in a dry and level ground area. The bundles should not be stacked more than two numbers or any other components. The bend in collecting electrode panels create severe alignment problem during erection. One number of collecting electrode panel per field will be supplied as erection spare. After completion of erection the spare electrodes if available can be handed over to the customer for future usage.
SPIRAL EMITTING ELECTRODES: -
The spike rods are dispatched to site in wooden boxes. The wooden boxes should be stored in a dry place. While unloading the boxes, care to be taken to avoid any damage to the electrodes. One number spike rod per field will be supplied as erection spare. After erection the remaining spare electrodes can be handed over to the
customer for future use.

SLIDING BEARING SUPPORTS: -
The sliding bearing supports (one per column) will be dispatched in individual wooden boxes. The sliding bearings should be inspected at site by the site engineer for The sliding
dimensions as per the bearing layout drawing issued for erection. bearings are stored in a clean and dry place until required for erection.
TRANSFORMER RECTIFIER SET: -
Before unloading of transformer and control panel it has to be checked for any physical damage of exterior components, leakage of oil, missing or damaged gauges etc. The transformer unit should be unloaded using lifting lugs provided in the
transformer unit. The transformers should be stored in a dry and level ground area. The control cubicles should be unloaded using the lifting eyes provided on the top of the panel. A pair of matched chokers should be used and do not wrap chokers
around the control panels.
The control cubicle will be covered with a cardboard
covering. This covering to be removed only after the panel has been placed in its original position. The control cubicles should be stored in closed area free from
sunlight, rain or dust.

INSULATORS: -
Porcelain cylindrical support insulators will be dispatched in individual wooden shipping boxes. The insulators should be handled carefully and stored in a safe place to avoid breakage. Do not stack the insulators. The insulator packing should not be opened until it was required for erection.
MICRO TAPPER PANEL
Micro tapper panel should be checked for any physical damage during transportation and to be stored in a clean and dry leveled area. The panel packing to be removed only after placing the panel in required position.
HEATERS AND THERMOSTATS: -
All heaters are to be checked for physical damage during transportation. heaters should be checked for its healthy condition before erecting the same.
MECHANICAL SAFETY INTERLOCKING SYSTEM: -
All the
The mechanical safety interlock should be checked with the bill of quantity and proper functioning of key arrangement. The interlocking system should be stored in a dry area.
NOTE:
All parts should be checked before storage against the bill of material. The storage area should be within easy access to the erection site to minimize excessive and expensive handling of materials.
ESP ERECTION PROCEDURE:
The step-by-step erection procedure for ESP erection is given below.
The given
procedure is only a guideline and it may vary in accordance with site condition
Step 01: Step 02: Step 03: Step 04: Step 05: Step 06: Step 07: Step 08: Step 09: Step 10: Step 11: Step 12: Step 13: Step 14: Step 15: Step 16: Step 17: Step 18: Step 19: Step 20: Step 21: Step 22:
Grouting of foundation bolts Erection of ESP supporting structure Fixing of sliding bearing supports Erection of casing support structure and casing panels Fitment of inlet and outlet gas funnels Erection of collecting electrode suspension system Erection of spike rod suspension system Alignment of collecting and spike rod systems Erection of inlet and outlet gas funnels Erection of inlet and outlet gas distribution systems Erection of ESP penthouse and outer roof assembly Erection of stair case and platform assembly Erection of hopper assembly Erection of collecting electrode rapping mechanism Erection of spike rod rapping mechanism Erection of inlet GD rapping mechanism Erection of monorail support structure and monorail beam Lifting of Transformer Rectifier Set Loading of High Voltage Emitting system to HV insulators Completing bus duct connection between HV insulator and TR set Erection of hopper level platform and internal walkways Erection of electrical equipments, purge air system and associated JBs and LPBs
Step 23: Step 24: Step 25:
Laying of power and control cables Laying of earth flat and earth pits Application of thermal insulation
ESP PERFORMANCE TEST PREPARATORY WORK

OBJECTIVE OF THE TEST: -
This test is to determine the performance of the ESP in the normal operating condition. It determines Inlet, Outlet dust concentration and efficiency of the ESP.
TEST PREPARATION: -
(1)
PRE-TEST MEETING:
A pre-test meeting should be conducted among the test team, customer and Consultant to discuss the test programme date, time, course of test and the Facilities in order to perform the test with accuracy and in a reasonable time and For a careful planning.
(2)
TEST POINT SELECTION:
Care should be taken in selecting the test points to the test in representative Manner. The selected point should have a straight uniform running duct before It. Normally test point should be selected where the flow and distribution is Uniform across the section of the duct.
(3)
REQUIRED PLATFORMS:
Temporary platforms required shall be provided at the measuring stations (i.e. at the inlet duct and out let duct) For supporting the weight of around 6persons in
addition to the weight of the measuring kit approximately 200 Kgs. Also platforms and ladders shall be provided to access these operating Platforms. If the test pockets are provided on the side of the duct, suitable stand should be provided to hold the sampling probe.
(4)
POWER SUPPLY AND LIGHTING FACILITIES:
Power supply of single phase 230 V AC shall be provided with proper switch boards at the measuring stations to connect the testing equipments. The testing time can extend till mid night. Hence proper lighting is required. (5) METEOROLOGICAL DATA:
The meteorological data like barometric pressure will have to be furnished by the customer for the computation of results. (6) LAB FACILITIES:
Laboratory facility is required for the heating, cooling, weighing and for analyzing the flue gas with the following apparatus such as (a) ELECTRIC OVEN :
The electric oven with a maximum of 200 degree centigrade and with a capacity to house 40 thimble jar for drying the empty filters before the test. The filters have to be kept in the oven for a period of about 2 hours. (b) DESSICCATOR :
This is required for cooling the thimbles after drying them in oven. Activated silica gel or equivalents are to be used for cooling. (c) BALANCE :
A precision balance with a capacity of 100 gms and having an accuracy of 0.1 mg should be used for weighing the thimbles. The balance used shall be checked periodically for zero setting.
(d)
FLUE GAS ANALYSIS
Two number of Orsat apparatus of flue gas analysers with necessary sampling probes are required at inlet and outlet to analyse the flue gas sample to determine the percentage of oxygen and carbon di-oxide for each test. (7) MAN POWER REQUIREMENT: The following man power should be arranged by the customer for Conducting performance test at free of cost to assist and help the performance Test team During the test. Unskilled labors 8 (To handle testing equipments) Boiler control room technician 1 ESP control room technician 1 Chemist 1 (To carry out Orsat analysis at sampling station)
OPERATIONAL CONDITION PREVAILING FOR TEST:BOILER OPERATION CONDITION: Boiler should be in steady operation condition prior to start of each test. It is recommended to complete the soot/wall blowing and other periodic process operations before starting the test and these processes should not be done during the test or taking sampling. It is important to control the excess air requirement limited to the recommended value and this has to be monitored periodically. The pilot traverse or the actual sampling should not be started until a reasonably steady state conditions have prevailed for at least half an hour. As it may not be possible to operate the boiler at constant load for considerable period of time during the test the variation in the boiler load or boiler output should be maintained within plus or minus 10% of the rated value.
ESP OPERATION CONDITION
ESP should be operated with all fields in working condition. Ensure for the uniform distribution of flue gas flow inside the ESP. The ash handling system should be in good working condition. All the rapping motors/EMIGI rappers should be trouble free. Check for any leakage inside ESP. It should have
proper insulation. Inspection doors should be tightened and checked for any leakage through door openings. It is recommended that all the rapping systems shall be operated on continuous operation for 5 minutes and the hoppers of the respective streams shall be evacuated before the start of the test.
PARAMETER TO BE MEASURED FOR THE TEST: -
Flue gas temperature Flue gas flow rate Inlet dust concentration Outlet dust concentration Pressure drop.
ESP TROUBLE SHOOTING

Introduction: -
Electrostatic Precipitator is mainly constructed out of static equipments and few moving parts in rapping systems. However, the ESP internals are subjected to
operated at a high loading and dirty environment under relatively high and unfavorable temperature conditions.
Any defects in the precipitator will lead to insufficient operation and a deteriorated performance or even complete shutdown of ESP.
The following major systems have to be checked during trouble shooting of ESP.
Electrical power supply system Electrode cleaning system Insulator compartments Inlet and outlet funnels Inlet and outlet GD system Emitting electrode suspension Collecting electrode suspension Hoppers Structural steels and sliding bearings Thermal insulation Dust characteristics
Typical
mechanical
and
electrical
failures,
their
possible
reasons
and
recommendations to overcome the failure in the above-mentioned systems have been tabulated.
SL. NO.
TYPE OF FAILURE
REASON FOR FAILURE
RECOMMENDED REMEDIAL ACTION
Thermal stresses. Uneven Clean and grind the support surface of top and bottom flange and ensure that support flange rubber gaskets are installed Crack due to creeping current on the inner surface of insulator due to conductive layer, dust or condensate.
01
Mechanical cracks in high voltage support insulator
Clean the insulator inner surfaces, if required replace the insulator. Check the healthy condition of heaters
Total failure of insulator Replace
the
insulator.
due heavy leakage current Check the healthy condition through dust or condensate of heaters Water leakage into bus duct b/w T/Rset & support insulator compartment wetting the insulator giving leakage current. Dry insulator. Check the bus duct for water leakage and tighten all the flanges with rain guards and asbestos rope.
02
Mechanical crack in high voltage bushing insulator
03
Mechanical crack in shaft insulator
Crack due to any misalignment of shaft Check the shaft insulator is insulator with rapper in tact and in line with the plunger causing uneven rapper plunger. loading of insulator. Misalignment of emitting electrode frame work with Align the emitting system to respect to collecting system correct position and replace after replacement of the damaged electrode. insulator or other repair work Improper rapping resulting in heavy dust layer over electrodes there by increasing sparking tendency Check all the rappers are in position and properly hitting the rapping rod. Rapping frequency can be increased suitably.
04
Electrical erosion of emitting electrodes due to heavy sparking
SL. NO.
TYPE OF FAILURE
REASON FOR FAILURE
The ESP should be operated within a maximum spark rate of 12 sparks per minute. It should be limited to 10 sparks per minute during normal operation. If the ESP has been worked for a long period it is recommended to replace all the electrodes for better performance. Check that the rapping plungers are properly hitting the rapper rods. Check the frequency and lift of rapper plunger adjust to a suitable value. to Replacement of Rapper rod plunger recommended
05
Dust build up on collecting electrode panels
Improper rapping
06
Rapper rod & Rapper plunger
Fatigue failure due continuous running
07
Air leakage through access doors
Replace the worn out Leakage due to worn out gaskets and close the gaskets or improperly doors airtight after closed inspection doors completion of works. Air leakage in to the pent house. Support insulator heaters are not working or set at lower operating temperature. It is rare to happen. Check the pent house insulator doors are sealed properly. Clean the insulators. Check the healthy condition of heaters. Replace the electrode
08
Condensation of ash on support insulators
09
Mechanical failure of emitting electrodes
10
Back corona effect
Excessive accumulation of Increase high resistive ash over frequency. collecting surface
the
rapping
11
Condensation of ash over insulators
Clean and dry insulators. Low operating temperature Check the proper function of flue gas. Moisture of insulator heaters. ESP gathered during shutdown should not be operated at temperature less than dew or low load operations. point.
SL. NO.
TYPE OF FAILURE
REASON FOR FAILURE
12
Sticking of dust over electrodes and difficult to dislodge
Maintain the temperature Ash dew point temperature inside ESP greater than will be low dew point temperature Improper welding. Leakage through cover flange provided in hopper chute. Check welding and seal all the leaking areas. Cover flange to be properly tightened with gasket. Provide necessary baffle plates to divert the flow into active zone
13
Air in leakage through casing and hopper
14
By passing of flue gas through ESP inactive zones
Improper gas distribution
15
Check for proper function of Inadequate thermal hopper heaters. Provide insulation or heating of sufficient insulation Plugging of ash hoppers hoppers. Malfunctioning of thickness. Check for ash conveying systems. proper function of ash conveying system. The rapping frequency may not be sufficient or the rapping system is not properly functioning. If the rapping frequency is much higher it will also lead to reentrainment.
16
Heavy re-entrainment of dust particles during rapping
Check the proper working of rapping system. Adjust the rapping frequency based on dust loading.
17
T/ R set readings No primary voltage No primary current No secondary current No secondary voltage T/ R set readings No primary voltage Normal primary current Normal secondary current No secondary voltage
TR controller failure, blown fuse, shorted SCR circuit, Find the problem and take misadjustment of internal remedial action ground Short circuit in the system after TR. Check for ground in bus duct, insulator Take necessary action housing or in ESP casing, based on type of failure full hopper, broken discharge electrode, broken support insulator.
18
SL. NO.
TYPE OF FAILURE
REASON FOR FAILURE
19
T/ R set readings Low primary voltage Normal primary current Normal secondary current Low secondary voltage T/ R set readings Low primary voltage Low primary current Low secondary current Low secondary voltage No sparking condition T/ R set readings High primary voltage No primary current No secondary current
High resistance short to ground inside field. Check for cracked insulators, clinker or foreign materials in discharge electrode
20
Problem in controller. Misadjustment or malfunctioning of controller. Check the T/ R controller for its settings
21
T/ R set secondary opened. Replace T/ R set
22
Unstable voltage and current
Control circuit misadjustment malfunctioning. surge protector
or Shorted
23
Heavy fluctuation in voltage and current
Broken or slack discharge electrode, unstable discharge electrode system or dust buildup on discharge electrodes Dust buildup in emitting electrodes, high resistive dust or higher dust loading, un-connected bus section
24
High voltage than normal Low current Sparking or non sparking condition Gradual voltage drop with steady current and sparking Gradual voltage drop with increasing current
25
Coating of dust on emitting electrodes Tracking insulators, hopper jamming
26
SL. NO.
TYPE OF FAILURE
REASON FOR FAILURE
27
Abnormally low or no voltage. High current Higher spark rate in one chamber only Low secondary voltage Low secondary current Sparking condition Low secondary voltage Low secondary current Non sparking condition Excessive emission while precipitator operation at maximum power Heater failure
Plugged hopper, shorted insulator, broken discharge electrode Ambient air in leakage Cracked HV support insulator, close internal electrical clearance, Controller problem
28
29
30
Controller problem
31
Adjust the rapping Frequent or inadequate frequency to required level. rapping, more flue gas flow Check the flue gas flow rate than designed and inlet dust loading. Short circuiting or resistance to ground low Replace the failed heaters Correct the ash handling system, check the hopper heaters for proper functioning, check hopper doors for proper sealing and also the cover flange in side chute.
32
33
Hopper level high indication and the field is being tripped
Malfunctioning of ash handling system, dust blocked near discharge point, air leakage into hopper, wet dust
34
Increasing system pressure drop Excessive corrosion of casing inside surface due to acid formation inside ESP
Dust buildup in flue gas inlet passage or in inlet gas Clear the flue gas passage distribution screens Necessary correction works Periodic The insulation may be to be taken. insufficient or damaged checking of insulation to be done.
35
SUB-VENDORS MANUAL
(BOILER BG059 & BG060)
DATA SHEET
MICRO TAPPER CONTROL PANEL

DESCRIPTION GENERAL DATA:
MAKE QUANTITY APPLICATION M/S. DSA ELECTRO CONTROLS PVT.LTD 1 X 2 NOS. CONTROL OF RAPPERS UPTO 100 NOS IN MATRIX OF 10 ROWS X 10 COLUMNS (MAX.) EACH RAPPER IS CONTROLLED FOR ITS LIFT (0-20 FT. LBS) AND ROUND TRIP TIME FROM 1 TO MAXIMUM OF 99 MINUTES IN A RANDOM SEQUENCE SUPPLY VOLTAGE SUPPLY FREQUENCY OUTPUT DETAILS : OUTPUT RATING PULSE DURATION SUCESSIVE RAPPER OPERATION INTERVAL LIFT ROUND TRIP TIME (RTT) NO. OF ROWS LEAD LENGTH AMBIENT CONDITIONS TEMPERATURE HUMIDITY PANEL PROTECTION SERVICE 25 45C 60 80% RH NON CONDENSING IP 54 INDOOR 0 TO 20 FT. LBS 1 99 MINUTES MAX. 10 ROWS MAX. 4 ohm LOOP RESISTANCE 220 V DC 10% 30 AMPS (MAX.) 50 MS TO 80 MS 1 SEC 415 V AC 10% SINGLE PHASE 50 Hz 5%
SPECIFICATION
SUPPLIERS ADDRESS:
M/S. DSA ELECTRO CONTROLS (P) LTD, UNIT 48, 1ST B, RAJ INDUSTRIAL COMPLEX, MILITARY ROAD, HAROL, MUMBAI - 400059
DATA SHEET
DUST LEVEL INDICATOR

MAKE QUANTITY APPLICATION TYPE MODEL INDICATOR COMPONENT M/S. EIP BULK CONTROLS PVT. LTD. 3 X 2 NOS. TO MEASURE FLY ASH LEVEL IN ESP HOPPER RF TYPE RF 550 DIGITAL 1. ELECTRONIC CONTROLLER 2. SENSING PROBE HEAD 3. COAXIAL CABLE TO CONNECT ELECTRONIC UNIT & SENSING PROBE (10m APPROX)
SPECIFICATION
PROBE
MODEL MOUNTING VESSEL TEMPERATURE INSERTION LENGTH RF-550 RT CB ESP HOPPER (3/4 BSP MOUNTING) 220C 220 MM
ELECTRONIC UNIT
MODEL TYPE SUPPLY VOLTAGE OUTPUT AMBIENT TEMPERATURE RF-550 RT EC SOLID STATE 230 V, 50 Hz AC DPDT RELAY O/P 5A @ 230V AC 10 C TO 60C
SUPPLIERS ADDRESS:
M/S EIP ENVIRO LEVEL CONTROLS PVT.LTD. B-130, SECTOR-X, NOIDA - 201301 UTTAR PRADESH.
DATA SHEET
TRANSFORMER RECTIFIER SET

DESCRIPTION
MAKE QUANTITY APPLICATION TYPE INPUT VOLTAGE OUTPUT VOLTAGE OUTPUT CURRENT CLASS OF INSULATION DUTY TEMP. RISE OVER AMBIENT CLASS OF BUSHING RECTIFIER TYPE
SPECIFICATION
M/s. HIND RECTIFIERS LIMITED, 3 X 2 NOS. TR SET FOR ESP STEP UP DOUBLE WOUND 415 V, 10%, SINGLE PHASE, 50 Hz 120 KV PEAK 600 mA MEANS ONAN CONTINUOUS 50C 36 KV, AC FULL WAVE BRIDGE RECTIFIER WITH POSITIVE TERMINAL EARTHED AND NEGATIVE TERMINAL BROUGHT OUT THROUGH SINGLE BUSHING
CONTROL TYPE OF CABINET VOLTAGE CONTROL ARC SUPPRESSION PROTECTION INSTRUMENTATION PROVIDED SIGNAL CIRCUIT VENTILLATION DESIGN AMBIENT TEMPERATURE POWER SUPPLY PAINTING INSTALLATION - TR SET - CONTROL CUBICLE CONTROL SUPPLY
BY MEANS OF SCR FREE STANDING PROVIDED PROVIDED IP 51 AS PER SUPPLIER STANDARD PROVIDED PROVIDED 50C 415 V AC, 3 PHASE, 50 Hz RAL 7032 SIEMENS GREY OUTDOOR INDOOR 230 V AC
TRANSFORMER RECTIFIER CONTROL UNIT:
SUPPLIERS ADDRESS:
M/s. HIND RECTIFIERS LIMITED, NO. 7/1, AVENUE ROAD, CHENNAI - 600 034. 1ST FLOOR, ANNA MANSION, NUNGAMPAKKAM,
-5CHAPTER - 3 DOS AND DONTS FOR YOUR POWER SUPPLY UNIT (Please ensures all the safety interlocks before switching 'ON)
1 2 3 4 Try to maintain your Panel room ambient low. Keep your panel and Panel room clean, dust free. Go through the instruction and maintenance manual carefully, before you start working on equipment. Whenever connection is removed and made again, ensure that the connection is made properly. Avoid loose joints, joint heating and consequent system shutdown. Trouble shooting chart for transformer rectifier is given in manual. Follow the thumb rules given in these pages, in case of problem with supply. Adhere to the maintenance schedule for electronic controller/T R Unit given in maintenance. During trouble shooting, try to use proper tools/ instruments as given in maintenance section. If the panel trips due to any fault, before switching on the panel, rectify the fault. Keep the records of all readings including ambient temperature, transformer oil temperature, etc. regularly. History card shall be maintained to analyze the cause of failure. In case the user requires services of manufacturer, a detail report of problem faced shall be sent for analyzing the problem and prompt service. Transformer shall be lifted to ESP rooftop after ensuring the healthiness. You find that there is a problem in ESP field, do not repeatedly switch on power supply. This will do good both to your power supply and ESP. Never pull out or inserts plug in connector in live condition. Switch off contactor and switch fuses unit before you insert/ take out connectors. Do not operate the equipment if there is a malfunctioning of control or protective circuit. When earth switch is in earth position please do not SWITCH ON TR Unit ACE.DOC
5 6 7 8 9
10
11 12 13 14 15
-6CHAPTER - 4 TRANSFORMER OIL SAFETY DATA SHEET

4.1 GENERAL PRODUCT MANUFACTURERS NAME 4.2 Transformer mineral oil IS:335 or IEC:296 class-I as per
Apar Industries Ltd. (Power Oil) Savita Chemicals Ltd.
HAZRDOUS INGREDIENTS /IDENTIFY INFORMATION HAZARDOUS COMPONENTS (SPECIFIC CHEMICAL IDENTITY : CAS COMPOSITION CAS NAME 64742-65-0 Pure hydrocarbon mineral oil Medium napphthenic hydrotreated distillate
4.3
PHYSICAL/CHEMICAL CHARACTERISTICS SPECIFIC GRAVITY(H2O= 1) VAPOUR DENSITY (AIR = 1) APPEARANCE AND ODOUR SOLUBILITY IN WATER 0.89 > 10 Water white with peculiar smell Insoluble in water 140C (ASTM-D 93) Above 250c VAPOUR PRESSURE(mm Hg) < 0.1
4.4
FIRE AND EXPLOSION DATA FLASH POINT (METHOD USED) BOILING POINT
FIRE AND EXPLOSIVE HAZARDS Slightly combustible liquid when heated above its Flash Point. This material will release flammable vaporous which can burn in the open or be explosive in confined spaces if exposed to an ignition source, must kept away from extreme heat and open flame. EXTINGUISHING MEDIA Dry chemical and carbon dioxide foam and water fog are effective but cause frothing. SPECIAL FIRE FIGHTING PROCEDURES Water may be effective but can be used to cool containers exposed to heat or flame. Caution should be exercised when using water foam as frothing may occur, especially if spread into containers of hot, burning liquid. ACE.DOC
-74.5 HEALTH HAZARDS SUMMARY OF ACTUAL HAZARDS Not expected to present a significant health hazard upon short term exposure. ROUTE OF EXPOSURE INHALATION EYE CONTACT SKIN ABSORPTION SIGNS AND SYMPTOMS No significant adverse health effects This product is practically non irritating to the eyes upon direct contact. No significant adverse health effects are expected to occur upon short-term exposure No irritation from short-term exposure. Do not ingest. Ingestion is relatively non-toxic unless aspiration occurs. No significant adverse health effects are expected to occur upon short-term exposure. Prolonged and/or repeated contact with the material produces skin irritation and inflammation. Personnel with pre existing skin disorders should avoid contact.
SKIN IRRITATION INGESTION
CHRONIC HAZARDS
SPECIAL HEALTH EFFECTS 4.6
PROTECTIVE EQIPMENTS AND OTHER CONTROL MEASURES RESPIRATORY Respiratory protection is not required under normal conditions of use. If vapor or mist is generated when the material is heated or handled. Use vapor respirator with dust and mist filter. Eye protection is not required under condition of normal use. Avoid prolonged and/or repeated skin contact, or wear impervious protective clothing. While leaving work, wash hands/exposed skin with soap & water. Use adequate ventilation to keep oil mists of materials below applicable standards. Wash hands with plenty of soap and water before eating, drinking etc. Take a shower after work. If general contact occurs, remove oil soaked clothing. ACE.DOC
EYE SKIN
ENGINEERING CONTROL
OTHER HYGENIC AND WORK PRACTICES
-84.7 EMERGENCY AND FIRST AID INHALATION Vaporization is not expected at ambient temperature and this material is not expected to be an inhalation problem under anticipated condition of use. In case of over exposure move person to fresh air. Immediately flush eyes with large amount of water and continue flushing for 15 minutes, occasionally lifting the eye lids. If pain or redness persists after flushing, obtain medical attention. Remove contaminated clothing. Wash contaminated area thoroughly with soap and water. If redness or irritation persists seek medical attention.
EYE CONTACT
SKIN CONTACT
4.8
SPILL AND DISPOSAL WASTE DISPOSAL METHODS Remove to storage or salvage vessels if permitted incineration may be practical. Shut off ignition sources contains spill and prevents it from entering waterways and sewers. Maximize product recovery for reuse or recycling.
4.9
ADDITIONAL PRECAUTIONS HANDLING STORAGE AND ECONTAMINATION PROCEDURES To avoid product degradation water contamination should be avoided and minimum feasible handling temperature should be maintained. Period of exposure to high temperature (>150C) should be minimized. Product degradation might increase health hazard risks. All information is based on data available from the mineral oil manufacturer. All the information is based on results gained from manufacturers experience and tests and is believed to be accurate. We undertake no responsibility either for the results derived from their adoption or possible position in apparent contrast.
GENERAL COMMENTS
ACE.DOC
-9CHAPTER 5 INTRODUCTION, DESCRIPTION & PRINCIPLE OF OPERATION

5.1 INTRODUCTION Electrostatic Precipitation is the leading and most effective method for removal of solid particles from the industrial flue gases. The Electrostatic Precipitator consists of a large steel chamber and the electrode system. The high voltage DC supply applied between the emitting and collecting electrodes, with the emitting electrode connected to negative terminal. The collecting electrodes are connected to the positive terminal, which earthed. When flue gas pass through the chamber because of the high DC voltage the solid particles are ionized and travel towards collecting electrodes and collected. The rapping mechanism raps the collecting electrodes and the dust drops in the hoppers. This is finally disposed off. 5.2 PRINCIPLE OF OPERATION The efficiency in the precipitation in the electrostatic precipitator is directly related to the level of attainable precipitation voltage. Therefore, the voltage appearing across electrodes should be maintained at the maximum level. That can be achieved without producing several sparking within the precipitator. This voltage level is defined as the `THRESHOLD of SPARKING and it varies with the configuration of the precipitator and the characteristic, temperature and velocity of the gas and other process parameter. Hence output current of power supply unit shall be capable of being varied over wide range to achieve the optimum condition. The control unit regulates the average value of the precipitator current in a closed loop control system. The current is measured by means of a current shunt. The precipitator current and thereby the corona power is adjusted by means of two anti-parallel Thyristor, which control AC voltage applied to the high-voltage transformer. The secondary voltage of transformer is rectified in a single-phase bridge rectifier and then applied directly to the electrostatic precipitator with a negative polarity. The SCR has fast response characteristics. This characteristic of SCR is utilized in control of ESP power supply. The precipitator voltage/current is brought down to zero, after every spark/arc and maintained it at zero for preset period and then built it at a fast rate, to the predetermined value. This method of control result in effective spark/arc quenching and at the same time helps in maintaining a higher average precipitator voltage. This results in higher precipitator efficiency. 5.3 DESCRIPTION OF POWER CIRCUIT The SCR controlled precipitator power supply system consists of Two units, the TRANSFORMER RECTIFIER UNIT (TRU) and ELECTRONIC CONTROLLER (EC). The T R Unit consists of HT transformer, linear reactor and Rectifier diode stack with voltage sharing resistor, hole storage condenser, HT feed back resistors and high frequency choke. All these components are oil immersed, and housed in a Tank. ACE.DOC
- 10 The components in the electronic controller are shown in the power circuit diagram. SW1 is the main fuse switch unit consisting of switch SW1 and HRC Fuses FS1-2. Aux. Transformer TR2 is provided for Cubicle light and socket supply. This transformer is provided with fuse FS3 and FS4 on input side. When the auxiliary power supply of 110V AC is made available through this transformer, the cubicle light switches ON in case of front door open. The cubicle light is interlocked to the front door by means of micro switch MS1 When the main switchfuse unit. SW1 is made ON; the power is made available to Aux. Transformers TR1 and TR3, ACE16, control card and also control for contactor coil, hooter, indicating lamps for various functions. K1 is main contactor. Switching ON and Off this contactor controlled by ACE16 Various interlocks are provided in the contactor circuit so that Incase of faults, the contactor will be switched OFF. When the contactor is switched ON, the AC supply is made available to the SCR regulator. This single-phase regulator consists of SCR1-SCR2 connected back to back. The snubber network consists of R1a, C1a, R1b & C1b provided across the SCRs for surge protection. Also Input surge suppression network is provided for the AC regulator protection. Current transformers (CT1-CT2) are sensing primary current to monitor primary current and sensing PY overload through thermal overload relay O/L. VM1 is the AC Voltmeter, which monitor the primary voltage of the transformer. DC meters are provided across the shunt and HT resistance column and are shown in circuit as AM2, VM2. All the interconnections for remote indication and alarm are wired to the terminal block TB1. Potential free contacts are made available for REMOTE ALARM, TRIP and HT ON. Facility is also available for REMOTE START, STOP. The ACE16 is also interlocked in such a way that in case of Process Fault, the unit is made to trip. For this purpose, NC contact from process fault has to be made available as shown in circuit diagram. MTR is the main transformer stepping up regulator output voltage to required kV. This Main Transformer Secondary voltage is rectified by means of Rectifier Bridge MR. This Rectifier stack consists of number of silicon diodes connected in series by means of suitable voltage sharing resistors and hole storage capacitors. The linear reactor L1 connected in series with primary of Main transformer for reducing the short circuit currents under sparking/ Arcing conditions. L2 is a high frequency reactor used for limiting the rectifier discharge current due to transformer capacitance during sparking. The Shunt (R) is secondary current sensing resistor and is connected in positive terminal of rectifier and GND. Overvoltage protector glow tube is used as backup protection in case of shunt open. High voltage DC sensing circuit consists of a number of high voltage resistors in series (RX) which convert high DC voltage to microampere. A micro ammeter calibrated in DC kV measures the DC output voltage. The HV resistance column is located in the TRU and Meter is mounted on the front panel of the control cubicle. Protection by means of over voltage protector is provided to this circuit. ACE.DOC
- 11 5.4 BUILT-IN TYPE EARTHING SWITCH The Earthing switch provided is oil immersed and is housed in the T R Unit tank. The switch is single Pole two way type. One position of switch is connected to earth and other position is connected to H T output terminal inside tank. The pole is connected to HT output bushing, which is ultimately connected to the field. The whole switch assembly is mounted on a plate, which is housed inside the transformer tank. The moving blade i.e. pole and fixed H T contact is mounted on suitable H T epoxy insulators. The earth position of switch is brought out through LT aux bushing for earth connection. For changeover, a handle is provided on the top of the T R Unit tank and is projected out on the T R Unit lid. This is manually operated handle. The field can be either connected to HT DC output or earthed by operation of this switch. A limit switch is provided such a way that when the switch pole is connected to earth position, NC contact of the limit switch which is wired in series with the starting circuit of main contactor will open and the T R Unit will be tripped. As long as switch is in the earth position the T R Unit cannot be switched ON. A mechanical stopper is provided for the switch handle at both positions on the T R Unit lid. This is to ensure that the switch blade does not over travel beyond its contact positions inside the tank. A provision is also made on T R Unit lid to mount the castle key interlock (Castle key interlock is not in HIRECT scope). The castle key interlock can be provided such a way that the switch can not be earthed when the T R Unit is in ON condition or if the switch is in earth position it can not be put back to H T position unless all ESP doors are closed and all safety interlock are complete. Thus with operation of this, Earthing Switch field can be earthed or can be connected to HT output internally with proper safety interlock. NOTE WHEN EARTH SWITCH IS IN EARTH POSITION PLEASE DO NOT SWITCH ON THE T R UNIT GENERAL OPERATING INSTRUCTIONS The SCR Controlled Power Supply Unit has sophisticated control and hence proper care has to be exercised in utilising the same. Before switching ON the unit please see that all the connections from main supply to the Electronic Controller and Transformer Rectifier Unit are properly made. See that the relays are properly placed and control cards are properly inserted in the proper place. Terminals 8, 9 and 10 of The Electronic Controller shall be connected to the terminals 8, 9 and 10 of Transformer Rectifier Unit respectively by means of a three core shielded cables. SCRs are mounted on the suitable heat sinks for cooling. When Unit is ON these heat sinks will be LIVE and hence DO NOT TOUCH THESE HEAT SINKS ON LIVE CONDITIONS. IT MAY RESULT IN SHOCK. It is recommended that no printed card is removed or inserted with the unit energised i.e. with SW1 in ON condition. Always switch OFF the SW1 before you insert or pull out the card. The power supply adjust it self to the varying Precipitator conditions by operating the constant current or spark rate spark rate mode. Hence no attention is normally required. ACE.DOC
5.5
1
2 3 4 5
- 12 6.0 DESCRIPTION OF 2 Way FIRING MODULE Ref.4C-6280

2-way firing module card consists of two channels for generating HF train of pulses for firing of Thyristors. The output (G-K) of each channel is isolated from the input side by the use of pulse transformers. Connect 17VAC at J1-3, J1-4 to generate +12V regulated power supply with help of diodes D1 - D4, L1, C1, C3 and regulated IC U1 (LM7812). Unregulated supply of +20V is available at point B, which feed to both section of the pulse transformer. Negative going variable Thyristor firing pulses (F = 50Hz) is applied between J1-1 and J1-2 of channel-1. U2 (IC LM555) generates high frequency pulses of frequency ranges form 8 to 10 kHz for a duration when Q2 is OFF. MOSFET Q1 (IRF 540) is driven by output of U2. Q1 switches at HF and acts as a buffer to drive the pulse transformer T1. This in turn energizes the pulse transformer T1. An isolated train of pulses is obtained at G1-K1, which can be used to fire an SCR. Operation of channel 2 is same as channel-1, same negative goin variable Thyristor firing pulses (F = 50Hz) is applied between J1-6 an J1-5. Output train of pulses is obtained at G2-K2. LED1 LED2 LED3 6.2 = +12V ON indication. = Channel 1 ON indication. = Channel 2 ON indication.
+5V/0.6A, 12V/0.5A POWER SUPPLY CARD (Ref.4C-6180)

The 8V AC signal is apply to connector J1-1 and 2, which fed to +5VDC regulated IC (U1) after rectified (D1-D4) and filter by capacitor (C1-C2). The Plastic package IC LM317T gives +5VDC-regulated supply and +5Vdc will be adjusted with help of VR1. The LED1 will indicates healthiness of the power supply. The 15V - 0 - 15Vac signal is apply to connector J1-4, 5 & 6. Diodes D6 to D9 rectify this AC signal and capacitors C6, C7, C10 & C11 filter the same. These unregulated signals are fed to the IC U2 (LM7812) and U3 (LM7912), which give regulated 12V Vdc power supply. The LED2 & 3 will indicate healthiness of the power supply. NOTE Same card can be use for other Power Supply using following components and input signal. OUTPUT VOLTAGE INPUT SIGNAL AT J1 4-6 COMPONENT FOR 5Vdc FOR 8Vdc FOR 12Vdc FOR 15Vdc FOR 24Vdc 8V - 0 - 8V 11V - 0 - 11V 15V - 0 - 15V 18V - 0 - 18V 25V- 0 - 25V LM7805 & LM7905 LM7808 & LM7908 LM7812 & LM7912 LM7815 & LM7915 LM7824 & LM7924
ACE.DOC
- 13 CHAPTER - 7 DESIGN AND FUNCTION

7.1 TRANSFORMER RECTIFIER UNIT The Transformer Rectifier Unit is build-up like a welded steel tank and filled with suitable coolant. The Tank is with totally sealed type construction provided with corrugated wall panels welded to the tank body. The T R Unit is provided without conservator and breather and there is no air column present in the tank. The cooling oil is filled upto the top of the T R Unit the marking on the oil level Indicator. The specially designed corrugated wall panel provides sufficient cooling area and also takes care of the oil expansion/contraction caused by the temperature differences in T R Unit. The corrugated wall panel gives more compactness to the Transformer Rectifier Unit and saving in steel and oil. The oil expansion and contraction is taken care of by below action of the corrugation itself. Thus with the elimination of the contact of the oil with external air, the whole arrangement becomes totally sealed type. Standard cooling liquid used is mineral transformer oil and meets the specifications according to IS-335. The oil is used as an insulating medium for the appearing high voltage and as a heat transfer medium as well. Immersed in the oil are the H V transformer M TR, Current limiting reactor L1, Rectifier bridge MR, HF choke L2, and the voltage divider network RX. This whole assembly is mounted at the bottom of the T R Unit and the lid is used just to cover the tank. Suitable neoprene gasket is provided between the lid and tank top flange to make it airtight. 7.2 THE H T TRANSFORMER MTR The HT transformer is a step-up single Phase core type transformer. The windings are vertically mounted on the two limbs of the core. The HV windings are of a special design to secure a proper distribution of the surge voltage occurring at flashover in the precipitator. The HV coils are wound in the form of disks and are connected in series to get required secondary voltage. An earth shield is provided between primary and secondary winding for protection. 7.3 CURRENT LIMITING REACTOR L1 The separate Iron cored choke is connected in series with the primary winding of the H T transformer and fitted on the top of the transformer. 7.4 H V RECTIFIER BRIDGE MR The single phase full wave rectifier bridge is made up of a large number of silicon rectifier diodes mounted on PCBs. Number of such PCBs are connected in series depending on the secondary voltage to form a rectifier bridge. A capacitor is provided in parallel with each diode for hole storage protection and a resister is provided in parallel with each diode to ensure equal voltage distribution across each diode. 7.5 H F CHOKE L2 The H F Choke is an air cored. The HF choke attenuates surge voltage and currents occurring at flashover in precipitator, especially at high frequencies. 7.6 VOLTAGE DIVIDER RX The voltage divider (RX) consists of number of thick film resistors connected in series to form a high voltage resistor. The resistors are mounted on PCBs and the PCBs are connected in series to get required voltage feedback. ACE.DOC
- 14 CHAPTER - 8 CONSTRUCTIONAL DETAILS 8.1 TRANSFORMER RECTIFIER UNIT

The Transformer Rectifier Unit houses the linear reactor L1, High Voltage step-up transformer MTR; the high voltage diode bridge rectifier modules MR, high frequency choke L2 and high voltage resister column RX. All these components are oil immersed natural cooled. In a completely covered weather proof, air cooled terminal box on side of transformer unit are housed the following components. 1 AC input terminals in the form of porcelain bushing marked C & D where the incoming power cables are to be connected. 2 Auxiliary bushing terminals for HV measurement marked 01, terminal for Py voltage sensing marked 02 and terminal for DC positive marked +VE. 3 Single pair protector box housing glow tube GLT2. 4 Aux. terminal blocks where the incoming control cables are to be connected. The wiring of the terminals of oil temperature indicator, dial type thermometer, sensing circuit is terminated on this Aux Terminal block, TB4. 5 The high voltage negative terminal of the DC output is by means of side mounted HV bushing insulator of 52kV class. The termination of the -VE is in the form of M12 stud. 6 The tank is made-up of robust leak proof welded steel structure rectangular in shape with suitable stiffeners wherever required. It is filled with adequate quantity mineral oil for insulation and cooling. Adequate cooling arrangement is provided wherever required by corrugated walls for ONAN cooling. The following fittings are provided on TR Unit tank. 7 Two Earthling terminals of M12 size near bottom end of side wall. The main earth bus is to be connected to these terminals for positive earthing of unit. 8 Tank lifting lugs These are provided for use during unloading of the T R Unit at site and for lifting the unit for installing at its place. 9 Top filter valve This is provided with a plug and is fitted on topside of transformer tank. 10 Drain cum filter valve This is provided at the bottom side of the tank wall and is of 1" size. Plug is also provided on this valve to protect it from mechanical damage and ingress of dirt.
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- 15 11 Dial Thermometer: The dial thermometer senses the temperature of the oil in transformer and gives indication on the dial fitted in pocket mounted on lid. The thermometer has two electrically free auxiliary contacts, which close at preset temp. The recommended settings are 95C for the alarm and 100C for trip contact. These terminals are wired to auxiliary terminal block for extending signal to control panel. 12 Pressure release valve This is a pressure release device mounted on the tank lid to protect against abnormal pressure build up inside the oil tank. This consists of an opening connecting the tank to a bypass. The opening is normally blanked by a spring loaded plunger. In case the tank inside pressure builds up to a value exceeding the pressure setting of the spring, the opening gets connected to the bypass relieving the tank inside of excessive pressure build up. The bypass is connected to outside atmosphere by means of an L bend pipe so that the oil which comes out does not spill over lid of a Transformer. 13 Pressure Switch This is a pressure sensing device mounted on the top of the Transformer Rectifier Unit, which trips the TR Set in case of excessive pressure in the TR Unit. The range of the pressure switch is 0-1.6 Bar adjustable. The switch is set to trip at 4PSI pressure and reset at 2PSI pressure. The changeover contact provided with pressure switch trips the T R sets when the pressure switch operates.
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- 16 CHAPTER - 9
INSTALLATION
9.0 9.1 TRANSFORMER RECTIFIER UNIT GENERAL The transformer rectifier unit is oil filled (ONAN) cooled. It is designed for outdoor duty suitable for mounting on the top of the precipitator as required. However it can be installed indoors also in the room. The electronic controller is of freestanding type suitable for floor mounting and is designed for indoor duty. Both, Control cubicle and Transformer Rectifier is designed to operate in a maximum ambient temp of 50C. INSTALLATION The T R Unit is preferably placed on rails with blocking facilities, ensuring the minor movement in all directions. When several T R Units are placed close to each other, the minimum distance between the two units must be 500mm. If the units are placed under environmental conditions, causing a drop in the cooling efficiency, the coolers must be cleaned more frequently. Cable entry into the LV junction box, is from bottom. The power line is directly connected to the LV bushings. ELECTRICAL COMMISSIONING NOTE When tightening, use counter force to ensure that the bushing bolt is not moved. This is to minimize the risks for bad connections inside and oil leakage as well. Flashover in the precipitator is generating surge currents and voltages in the system. To avoid surge between different units in the system (May be kV), it is very important that the ground wiring is made up according to figures. The main ground terminal of the T R Unit in the positive DC connection of the rectifier as well. The ground terminal is has to be connected to the precipitator ground terminal via the tank ground terminal. A grounding link has to be made over every bus duct joint, between the rectifier and precipitator, before commissioning. When a safety switch is installed for disconnecting the primary side of the T R Unit during maintenance work, the aux. contact of this switch preferably has to interlock main contactor. 9.4 PRE-INSTALLATION CHECKS/TESTS - RECTIFIER TRANSFORMER Check the di-electric strength of oil in the main tank. Samples should be taken through the drain/sampling valve provided at the bottom of the transformer tank. It should not break down below 50kV across 2.5mm gap. If the transformer oil fails this test, it should be filtered till the above values are achieved. 1 Checking of insulation resistance with 1000 V DC megger 2 Remove all bushing external connections. Short primary side bushing i.e., C, and 02. Short Secondary side bushing i.e. 01, +VE and -VE. Connect the Meggar between primary to earth, Secondary to earth and primary to secondary. The minimum value of insulation resistance should be as follows: ACE.DOC
9.2
9.3
- 17 Primary to Earth 100m Secondary to Earth - 750m. Primary to Secondary 750m 4 If any of the above IR values are low the transformer oil should put on circulation through filter plant till IR value comes to required value. 5 Reconnect the earth connection to the +VE bushing 6 Check oil level and top up if found necessary. 7 Carry out no load test as mentioned by applying rated primary voltage(As indicated on the T R Unit rating plate). This voltage shall be applied between terminals C and D in a terminal box. Note that the no load current should be less than 6% of the full load current The voltage should be applied for At least 10 minutes in which time neither the input current should rise nor should there be any unusual noise from the transformer tank. If the current is high or any tracking/arcing noise is heard from the tank, the Marketing Division/Branch Office should be informed and the transformer should not be lifted to ESP. CARE MUST BE TAKEN TO ISOLATE THE AREA WHEN CARRYING OUT NO LOAD TEST, AS FULL RATE HV APPEARS AT -VE BUSHING. UNAUTHORISE PERSON SHOULD NOT BE ALLOW NEAR THE AREA. 9.4.8 9.5 9.5.1 1 2 3 4 5 6 7 8 9 After completing above steps the transformer can be lifted to ESP. PRE-INSTALLATION CHECKS/TESTS : CONTROL CUBICLE Checking of insulation resistance with 500V DC Meggar. Remove ACE16 controller from panel. Remove auxiliary contactors Remove firing module and other controller card Remove fuses of auxiliary transformer wired to cubicle light Switch ON Switch fuse unit SFU. Mechanically short Main Contactor K1 Short input and output terminals i.e. A, B and C, D. Short Gate, Cathode & Anode of the SCRs. Short input surge suppression condenser. Connect Meggar between line & earth. The minimum value of insulation resistance should be 5M. If IR value is less than 5M. 2KW heater may be placed inside the cubicle for drying it till the IR value comes to required level, Considerable improvement in IR value can be obtained by thoroughly cleaning the insulation parts and making it free from dust and moisture by clean cloth. CHECKING OF OTHER COMPONENTS Checking of all the fuses and their correct rating. Ensure that all control cards are pushed in properly. Ensure that all the contactors are connected properly. Clean the cubicle using cloth and blower to remove all the rust from the surface of all components especially SCR and heat sinks. ACE.DOC
9.5.2 1 2 3 4
- 18 9.6 INSTALLATION - CONTROL CUBICLE The control cubicle is suitable for floor mounting and foundation holes are provided for fixing the cubicle to the foundation of necessary. The control room shall be air conditioned for proper cooling to make it dust free. Before making interconnection to the Main switch board, control cubicle, the TR. Unit and the precipitator, the circuit enclosed in the this manual shall be carefully studied for familiarizing with interconnections. All wedges and the like of which are fitted by the manufacturer to prevent damage during transit and are identified by caution label, should be removed and all items which have been tie-up to prevent movement during transit must be released. INTERCONNECTIONS/CABLING :The various power and control connections in the control cubicle and T R Unit are terminated on suitable terminal board and the high voltage connections on suitable bushings. All the control interconnections shall be done by means of shielded cables. The power connections shall be done by means of suitable power cables as per standard practice. The cable sizes for various ratings are given in the table in the General Arrangement Drg. for the control cubicle. The HT connections are done in an enclosed ducting. Earthing of T R Unit and the control cubicle should be done properly and for this purpose the stud has been provided on the T R Unit whereas in the control cubicle an earthing bus and two numbers of studs have been provided. PRE-COMMISSIONING CHECK UPS The following pre-commissioning check-ups may be carried out on transformer 1 Disconnect the transformer rectifier from the control cubicle as well as from the precipitator. Check IR value of primary and secondary windings as outlined. 2 Apply a variable AC voltage to the transformer Primary terminals C & D/C in the terminal box by means of an Auto Transformer. A voltmeter and an ammeter may be used for measuring the voltage and current shown in the circuit. An HRC fuse of 10A capacity must be incorporated in series with the transformer primary to protect the variac. Increase the voltage gradually and note the increase in the current. Observe a current at the rated voltage. This reading shall be as per the reading in the test profarma and is always less than 6% of the rated Py current. If the T R Unit is faulty then a ammeter may kick suddenly at some point. The voltage shall be brought to zero immediately. This shall be notified to our Marketing Div./Branch office. 3 Testing of the control cubicle separately on resistive load. Refer ACE16 controllers installation instruction.
9.7
9.8
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- 19 CHAPTER - 10 COMMISSIONING AND OPERATION

10.1 OPERATION Generally check the following No transit damage. No loose components or connections during transportation. The cabling is made up according to contract documentation and according to mandatory requirements of the authorities if applicable.
PLEASE OBSERVE THAT WRONG CONNECTION MAY CAUSE SERIOUS DAMAGES ON THE EQUIPMENT, WITH A LOT OF COSTS INVOLVED, NOT COVERED BE THE WARRANTY. WHEN IN DOUBT, DO NOT HESITATE TO CONTACT US.
Check in the T R Unit that > Check that the Bushings are not damaged or moved. No oil leaks are visible. Retighten the top nut if necessary. The grounding is made as follows > The main ground terminal of the T R Unit is the POSITIVE DC connection of the Rectifier as well. The main ground terminal is located on the LV junction box and has to be connected to the precipitator ground terminal via the tank ground terminal. The grounding link has to be made over every LV bus duct joint between the rectifier and precipitator. Before commissioning, make a special check on every ground connection. When the safety switch is installed for the disconnecting the primary side of the T R Unit during maintenance work, the auxiliary contact of this switch preferably has to interlock the Main Contactor. The ground connection to the measuring shunt is intact. The H V bus duct is connected to ground.
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- 20 10.2 FUNCTIONAL CHECK

WARNING AT ANY OCCATION AT POSIBLE CONTACT WITH LIVE PARTS, WHEN WORKING WITH EQUIPMENT, SWITCH OFF THE MAIN SWITCH AND CONNECT THE H V OUTPUT TO GROUND, IF APPLICABLE. All the check functions important for the operation and for security reasons are available in connection with the commissioning. ALARMS Simulate faults according to the different procedures below and check that alarm is indicated on the control Panel. Also refer the Circuit diagram to avoid wrong steps. 1 Oil gas Alarm Link the connections on level indicator, located in the monitoring device. Check that alarm indication is obtained. Restore the level indicator. 2 Oil High Temperature Alarm Link the connections on thermostat located in the monitoring device. Check that alarm indication is obtained. Restore the thermostat. AUXILIARY CIRCUIT The tripping facilities in the interlocking circuit have to be checked after the installation, to ensure proper functioning. Make sure that loosens wires do not touch any live parts. Proceed as below. 1 Disconnect the one of the connections on the dial thermometer located in the monitoring device. Check that the Rectifier cannot be switched on. Restore the thermostat. 2 Disconnect the one of the connections on the pressure Switch located on the monitoring device. Check that the Rectifier cannot be switched on. Restore the pressure switch. 3 If both the Control Cubicle and the T R Unit are found all right then the connections to the Control Cubicle, T R Unit and the precipitator chamber shall be made again.
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- 21CHAPTER - 11
MAINTENANCE
11.1 PREVENTIVE MENTENANCE Warning BEFORE STARTING ANY MAINTENANCE ON THE EQUIPMENT, MAKE SURE THAT NO LIVE PARTS ARE ACCESSIBLE BY ANY PERSONEL.
GENERAL This Rectifier needs normally very little maintenance, but to ensure proper duty and to minimize the total maintenance coasts, it is advisable to carry out some activities. The period of time between each maintenance depends on the environmental conditions and duty. Accordingly, the time interval must be determined by operational experience. CLEANING To minimize the risks for excess temperature in the T R Unit, clean the cooling elements and the tank-sides at necessary time intervals. Minimum annually. OIL TESTS To avoid damaged HV components, check the insulation condition of the oil every fifth year. The oil sample must be taken at dry weather and in dry containers. The suitable volume sample is about 200-300 milliliters, taken out from the bottom test/drain valve. The sample may preferably be sent to a suitable laboratory to make analyses of mainly the flash over limits, the isolation characteristics, the loss factor and the water content. If the analysis shows that the oil does not meet the specification, or at least very closed to, it has to be exchanged/ filtered. Water together with particles can be removed in the paper filtering press. The filtering is preferably carried out during about 10 hours, with the Rectifier in short circuit operation. OIL LEAKAGE CHECKS Larger oil leaks are monitored by oil level indicator and indicates low oil level alarm. Visual check is preferably carried out regularly. If leaks occur in the bushing insulator during the first period of duty, the top nut has to be retighten to the correct torque stated below. Exchanging of the top O ring of the bushing insulators can be done without draining any oil/ However, a small amount of air will leak during the exchange. Proceed as follows. 1 Make sure that the power supply is switched OFF and locked before starting any work on the unit. 2 Disconnect the wiring to the bushing. 3 Prepare tools and O-ring for a quick exchange. Preferable apply perma-tex. on the O-ring tightening surfaces. 4 Disconnect the fixing nut and washer on top of bushing. 5 Remove the top porcelain ring the rubber O-ring. Make sure that the bolt is always towards you in order to minimize leak of liquid. ACE.DOC
- 22 Fit the new O-ring. Fit the porcelain top ring and the rubber O-ring, the washer and the nut. Before tightening, make sure that the bolt is centered to the hole in porcelain body. 8 After 48 hours, retighten with torque according No. 8 9 If the distance between the porcelain, on both sides of the O ring, after the final tightening is less than above 1mm, an additional plain rubber washer may preferably be placed on the top of O-ring. This will equalize the difference in size of the concave space for the Oring and give better tightening. 10 Reconnect the wiring. STORING INSTRUCTIONS Store the equipment preferably in a dry well ventilated space. If this type of area is not available, make provisions for avoiding humidity to make any harm on the equipment. This can be achieved by wrapping with water proof paper with sufficient desiccant inside. If to be store in the transport packing, open the packing and check for transport damages, entered water or oil leaks. By approved checks, place some desiccant inside and restore the package. The package must not be placed outdoors. TROUBLE SHOOTING WARNING TO AVOID PERSSONAL INJURY, DO NOT PERFORM ANY SEVICING UNLESS YOU ARE QUALIFIED TO DO SO. Methods for electrical trouble shooting, described in the following chapter, are base on use of an ohmmeter with maximum 6 Volts measuring voltage and a multi-meter with input resistance of minimum 20000 ohms/Volt DC and 1000 Ohm/V AC. Instruments with other data are possible to use if influences on measured values are calculated. At any error indication in the ESP installation, the error must be localized to either the rectifier or the precipitator with surrounding equipment. When an error is indicated to be in the rectifier, start to carry out the open circuit and short circuit test described below. If both tests are approved the rectifier is in all probability correct. If any of the tests are not approved, proceed on suitable trouble shooting according to error indication occurred. 11.4 OPEN CIRCUIT TESTS PROCEDURE 1 Switch OFF the Rectifier. 2 Isolate the precipitator from the HV output. If an isolator is not available, a part of the HV busbar has to be removed. Please note that ground connections are properly made of both sides of parts to be removed. After the busbar removal, remove ground connection on rectifier HV output 3 Set the precipitator current limit to about 20%. 4 Switch ON the Rectifier. 5 Set the precipitator voltage limit to maximum. ACE.DOC 6 7
11.2
11.3
- 23 6 7 11.5 If the kV-meter shows more than 80% of the Rectifier nominal precipitator voltage, the test is approved. If the voltage is limited to a low value, proceed the trouble shooting in the controlling and regulating circuits.
SHORT CIRCUIT TESTS 1 Switch OFF the Rectifier. 2 Connect the H V output to the ground. 3 Set the precipitator current limit to about 20%. 4 Set the precipitator voltage limit to maximum. 5 Switch ON the Rectifier. 6 Check that the current is increasing slowly and is limited to a value, the corresponding to set current limit. 7 Increase the current limit setting to 100%. 8 If the precipitator current increase to the Rectifier nominal precipitator value, the test is approved. 9 If the current is limited to a low value, proceed the trouble shooting in the controlling and regulating circuits. TESTS ON H V TRANSFORMER 1 Switch OFF the Line voltage. 2 Switch OFF the Rectifier. 2 Disconnect the incoming power line on the LV bushing insulators 3 Isolate the precipitator from the H V output. Also refer to open circuit test Item-2. 4 Connect an single phase variac in series with an A-meter. (0-15A) to the LV bushing insulators for the power line connections. 5 Increase the variac voltage to about 90 % of nominal input line voltage. The output HV shall be minimum 70% of nominal HV. 6 Low voltage as a result of item 5 may depend on interruption in HV transformer, Rectifier bridge or voltage divider for the kV-meter. Also the kV-meter itself may be faulty. 7 In a A-meter reading is already maximum at a very low variac voltage, the Rectifier bridge is very likely to be short circuited. Also the kV-meter itself may be faulty at the same indications but it is more unlikely.
11.6
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- 24 11.7 INTERCONNECTIONS/CABLING The various power and control connections in the control cubicle and transformer rectifier are terminated on suitable terminal boards and the HV connections on suitable bushings. All the control connections shall be done by means of 2.5mm2 control cables. However the connections from the shunt and HV metering circuit on the transformer rectifier unit to the control cubicle should be done by means of shielded cables. The power connections shall be done by means of the cable sizes for various ratings are given in the table in the General Arrangement drawing for the cubicle. The HT connections are done in an enclosed ducting. Earthing of The T R Unit and the Control Cubicle should be done properly and for this purpose a M12 stud has been provided on the transformer rectifier unit whereas in the control cubicle an earthing bus and two numbers of M12 studs have been provided. 1 Disconnect the transformer rectifier from the control cubicle as well as from the precipitator. Check IR value of primary and secondary windings as outlined. 2 Apply a variable AC voltage between the transformer primary terminals (C-0 in terminal box) by means of an Auto transformer. A voltmeter and an Ammeter may be used for measuring the voltage and current as shown in the circuit diagram fig.2. An HRC fuse of 10A capacity must be incorporated in series with the transformer primary to protect the variac. Increase voltage gradually and note the increase in the current. Observe the current at the rated voltage. This reading shall be as per the reading in test Performa and is always less than 6% of rated primary current. If the transformer rectifier is faulty then the ammeter may kick suddenly at some point. The voltage shall be brought to zero immediately. This shall be notified to our Marketing Div./Branch office.
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- 25 11.8.1 SR. NO. 1. CONTROL CUBICLE MAINTENANCE SCHEDULE ACTION TO BE TAKEN IF INSPECTION IS UNSATISFACTORY If required these may be touched up with black paint Matt finished to improve heat dissipation.
INSPECTION ITEMS TO INSPECTION FREQUENCY INSPECT NOTES Monthly Heat Sink Clean thoroughly
2 3 4 5 6 7 8 9 10
Monthly Monthly Monthly Monthly Quarterly Quarterly Quarterly Yearly Yearly
SCRs
Connections Tight connection is required.
Electrolytic Leakage of Replace condenser. capacitor electrolyte Paper condenser Resistor/ condenser Contactor Switches Push Buttons Meters Power Oil leakage Burning surface Replace condenser. Replace resistor.
Pitting on Replace pitted contacts of contactor contactor. Free operation Free Operation Calibrate Tightness If not replace. If not replace Overhaul/recalibrate or replace as required. If mechanical tightening does not improve bad joints, its surface should be cleaned with 00 size emery paper, smeared with silicon grease and then tightened Replace/rewired overheated coil. Clean or dry out if value is low.
11 12
Yearly Yearly
Contactor Complete system
Coil connection Insulation resistance
11.8.2
TRANSFORMER RECTIFIER.
The transformer rectifier shall be maintained as per standard practice for the maintenance of HT Transformer as per IS-1886, code of practice for maintenance of transformers may be used as guidance. The Transformer may be cleaned and repainted if necessary, Clause 12.2 of IS-1886 is taken as the guidance in preparing following. ACE.DOC
- 2611.8.3 Sr. No. 1 TRANSFORMER MAINTENANCE SCHEDULE Items to Inspect Inspection Notes Action to be taken if inspection is unsatisfactory
Inspection Frequency Monthly
Oil Level in Check Transformer oil If low, top up with dry oil. Transformer level Examine transformer for leaks. Relays, Alarm Examine relays. Circuit etc. Loads (Amps) Check against rated fig. Voltage Bushings Check against rated fig. Examine for crack and dirt deposit Clean components and replace contacts. * * Clean or replace Loosen the check nut, adjust pressure screw and lock by check-nut. Take suitable action to restore qty. content of oil Take suitable action to restore qty. content of oil
2 3 4 5 6
Monthly Monthly Monthly Monthly Quarterly
Pressure Operating and release valve resetting pressure Oil in transformer Oil in transformer --Check for di-electric strength Check for Acidity strength
7 8 9
Yearly 2 Yearly 5 Yearly
Overall inspection Wash by housing down with including lifting of core clean dry oil. coils.
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11.8.4 Sr. 1
- 27 Trouble Shooting Chart for Transformer Rectifier Unit

Symptoms Probable cause
Remedy
Operation of oil Output current drawn is temp-HIGH-I excess of rated capacity alarm Operation of Oil 1 Overloading of unit Temp-HIGH-II 2 Overheating of windings alarm Operation of 1 Internal short circuit Pressure switch between turns 2 Short circuit between phase and earth. 3 Insulation break-down of major nature 4 Dielectric strength of Oil.
Reduce operative current Check temp. of transformer. Oil Ensuring separate thermometer in thermometer pocket provided Check for any blackened turns. Replace complete section Check clearance between core & Py/Sy winding. Make adequate clearance if found short. Remove Py/Sy coils. Insulating material & replace by new one. Filter/centrifuge the oil till dielectric strength as per IS-335 is achieved Check and replace the HT connection leads. Replace arm by new module.
TRU draws 1 HT -VE lead may be heavy current touched earth when energized 2 Rectifier stack arm separately by shorted. dimmerstat Low oil level even after topping up. 1 Leakage of oil through drain/filter valve.
Tight top filter valve & bottom drain/ valve. Apply sealing compound if leakage found between pipe treads
2 Oil leakage through BH Tighten the petcocks and relay petcock. replace if found faulty. 3 Oil leakage through gasket. 6 Dust collected in input box. 1 Input cable gland may not be matching. Change gasket by fresh one. Change the gland plate and gland to suit cable glands.
2 Seal on cable gland for Fill with M seal gap between BH relay wiring may be cable and its glands. Tighten removed cover bolt. 3 Loose cover bolts. 4 Gasket on gland plate/ cover might has removed Tight the cover bolt Put gasket on gland plate & cover. ACE.DOC
- 28 CHAPTER-12 AUTOMATIC CONTROLLER FOR ELECTROSTATIC PRECIPITATOR 12.1 INTRODUCTION OF ACE-16 The 'ACE-16' controller is an advanced microprocessor based system to monitor, execute certain algorithms and adjust automatically the ESP operating conditions and to provide optimum usable power to ESP at all times. Once programmed by the operator, it automatically accommodates the changing load, and input conditions without any manual adjustments. Field programmability of wide range of operating parameters permits an extremely high degree of flexibility. It automatically selects and optimizes ESP electrical operation based on field programmable parameter settings and feed backs from load. HARDWARE DESCRIPTION The 'ACE-16' is a microprocessor based fully digital controller used for control and optimized operation of Electrostatic precipitator (ESP). It consists of power supply, logic circuits, microprocessor, peripherals, buffers, opto-couplers and Analog circuits, key board and LCD display housed in one box. It has removable printed circuit boards; all are interconnected through flat cables. The controller consists of following boards. 1 Front Facia board. 2 Power Supply Board. 3 Main PCB Board. FRONT FACIA BOARD: Front Facia Board consists of A B C A 5 x 7 matrix , 2x16 character LCD module Dome type keyboard, with 32 keys. Individual LEDs are provided for some specific indication
12.2
All these are mounted on the front facia of the controller and connected to the Main PCB through easily removable flat cable assemblies. Individual LEDs are provided for some specific indications such as ON, OFF, REMOTE/LOCAL and READY TO START signals on the front facia. In addition, separate LEDs are provided to identify each of the external fault conditions on the Main PCB. KEYBOARD: The keyboard has 32 keys and a window for LCD display. The keys are arranged as below on front facia.
ON OFF
READY TO START
IDC
2 5 8
3 6 9
INR
IDC
T-QNCH
LAMP TEST
VDC 4 SPARK 7 RATE STATUS 0
DCR IDC SETBACK T-RCVRY SPARK MAX-PARK T-FRST TEST RATE RAMP PASS ENTER/ RMT/ ENERGY BACK CRNA CNTL WORD RESET LOCAL CTRL
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- 29 2 POWER SUPPLY BOARD: Power supply is industrial grade SMPS with following specification. Input : 230VAC,50Hz.Output:+5V,4A,+12V,1A,-12V,0.5A. Regulation: 1% MAIN PCB BOARD: The main PCB contains all the digital logic, analog circuit opto-isolators and static relays. The ACE-16 main PCB has a high level of integration of components, and also designed to provide good noise immunity. Display and keyboard are connected through flat cable to main PCB. The hardware modules on the main PCB are as follows MICROPROCESSO74R: The `ACE-16' is based on Intel 8088, which has an internal 16-bit architecture with external 8-bit data interface. READ/WRITE MEMORY (RAM): 32KB static RAM. In addition to this, there is 2KB of EEPROM /battery backup RAM. READ ONLY MEMORY (ROM): This is 64KB EPROM contains program codes & is non volatile ANALOG INPUTS: Two analog inputs are used for control. 1 0 - 1V corresponding to 0 100% rated current 2 0-400 micro Amp corresponding to 0 100% rated voltage A/D CONVERSION: Analog to Digital conversion is done by 8 bit ADC that gives better than 1% accuracy. INPUT /OUTPUT PORTS : It is used for sensing external alarm and status conditions. These inputs are optically isolated. Conditions include, Oil pressure high, Ext. overload, SCR Over temperature, Transformer Over temperature, Rapper ON, Remote ON/OFF, Process fault, Remote ACCEPT/ RESET. Potential free contacts are required for faults and status signals. Output ports are used for switching ON/OFF trip relay and annunciation relay. At the back of the controller the following LEDs are visible. LED L1 L2 L3 L4 L5 L6 L7 L8 L9 L10 L11 INDICATION LED INDICATION LED L24 L25 L26 L27 L28 L29 L30 L31 L32 L33 L34 INDICATION Remote ON/OFF Oil Temp. 1 Remote Reset Oil Pressure High Contactor ON Safety Line Oil Temp 2 SCR Temp High Thermal overload Ext. Overload Process Fault ACE.DOC Spark L12 Not used Under voltage L13 Not used Over Voltage L14 Contactor ON TXDA L15 Contactor OFF RXDA L16 Alarm Trip TXDB L17 Alarm Non trip RXDB L18-19 Not used SCR1 ON L20 Not used SCR2 ON L21 Not used Not used L22 Beeper ON Not used L23 Local/Remote ON
- 30 MECHANICAL DATA: Box Dimension Panel Cut out Full Frame 12.3 275mm X 235mm 285mm X 244mm 327mm X 267mm X 180mm
START UP PROCEDURE: The moment the power is applied to controller it goes into "SELF TEST " routine. In this routine it carries out following tests.
1 EPROM Test is carried out by check sum verification. 2 RAM and EEPROM test during which there are several writing and reading operations to/from the RAM cells and EPROM are carried out. 3 ADC test is carried out by several reading operations and comparison of readings. If any of these tests fails error message will be displayed on LCD module. SAFETY LINES Safety line is hardware interlock for fault. Unless safety line is healthy unit can be switched ON. Healthiness of safety line is indicated by 'READY TO START' LED. Whenever fault is persisting 'READY TO START LED blinks. OPERATION This section explains functions of keys and different access levels of parameters. The control keys provided for switching on and off Rectifier Unit are ON and OFF. Indication key READY TO START is provided for checking status of healthiness of Unit. LAMP TEST key is provided for checking healthiness of LED provided on front facia. The keys dedicated for displaying measured values and the statuses of the System are IDC, VDC, SPARK RATE and STATUS. The access to parameter changes is limited at various levels, however, parameters can be viewed by INR and DCR keys without password. LEVEL1 This is a normal operator level. (Setting up the current limit, NEC, IDC SETBACK etc.). LEVEL 2 This is engineering level.(Setting of blocking time, quench time etc) LEVEL 3 This is specialist level.(Setting of start up & testing parameters, rated values etc.) Changing parameters related to level 2 and level 3 require keying in of Passwords. All parameters on level 1 and level 2 have relevant keys, whereas level 3 parameters require a table reference and special code. Example <PASSWORD> 74 <ENTER/RESET> Keying in of an illegal value for a parameter results in the following display indication "ILLEGAL VALUE" ACE.DOC
- 31 Keying in a key not expected by the system in a given context. For e.g. an attempt to change a level 2 parameter from level 1, the display will indicate the following text " ILLEGAL KEY ". The keys dedicated for displaying and changing level 1 parameters are IDC LIMIT IDC SETBACK MAX SPARK RATE ENERGY CONTROL The keys dedicated for displaying and changing level 2 parameters are T QUENCH T RECOVERY T FAST RAMP BACK CORONA CONTROL The keys to be pressed for displaying and changing level parameters are combinations of : PASSWORD CODE ENTER/RESET INR/DCR ENTER/RESET KEYS FUNCTIONS: CONTROL KEYS: 1 ON: The depression of the key turns on the power contactor. 2 OFF: The depression of the key turns off the power contactor. READOUT KEYS: Given below is the listing of the various keys, which are used for readout of measuring values and the status of the system. 1 I DC Display indication of the mean value of the precipitator current " IDC xxxxmA 1. " Range is from 0 to nominal value. 2 V DC Display indication of the mean value of the precipitator voltage. " VDC xxx.x kV" 3 SPARK RATE Display indication of the Sparkover frequency. " SPKRATE xx/m" The default display of the system is always IDC. If the user has pressed any other key to display a required parameter, but hasn't changed the value and if three minutes have elapsed, then system switches back to default display IDC. 12.4 LEVEL 1 PARAMETERS: All parameters can be displayed by depressing the concerned function key. Once the parameter is displayed, it can be changed by simply keying the new value followed by ENTER/RESET. ACE.DOC
- 32 No password is required when changing these parameters. Keying in of the first digit passes from left to right. The acceptance of the keyed parameter is indicated by switching off the display for one second and the same parameter is displayed for three min. (changes in the same value can be done within min). However, in case of wrong keying in or illegal value a fault indication message is displayed and the original value of the parameter is retained. The keys which result in a read outs of level-1parameters are listed below. 1 IDC LIMIT: Displays the current limit of the system. The value ranges from 0 to nominal value. "IDC LIMIT xxxxmA" Default value 99 mA 2 IDC SET BACK: The depression of the key results in the display of current setback. The setback values ranges from 5mA to 20% of I DC NOM. " SET BACK xxxmA " Default value 30 mA. 3 MAX SPARK RATE : The key serves to set the maximum Sparkover frequency. "MAX SPKRT xx/m" Default value 12/m The value ranges from 1 to 60 Sparkovers /min. 4 ENERGY CONTROL: This key activates the energy control mode. Initial activation of the key results in the following display "NEC xx " Default value = 1. This parameter sets the cycle time for energy control operation. NEC is entered only in odd values from 1 to 99. <NEC> = 1 corresponds to normal operation. 12.5 LEVEL 2 PARAMETERS All parameters can be displayed by depressing the concerned function key. Changing parameters related to level 2 requires special password. The keys which result in the read out of the level 2 parameters are listed below : 1 T QUENCH : Displays "quench time" after type 2 Sparkover. "T QUENCH xxxms" Default value 40 mS. The value ranges from 5 to 100 m sec. 2 T RECOVERY : Displays the parameter rise time after a Sparkover. The value ranges from 40ms to 1000ms. "T RECOVERY xxxxms" Default value 99 mS 3 T FAST RAMP : The depression of the keys results in the display of time parameter after a Sparkover. If the measured time exceeds the parameter "T FTS RAMP", there is a change from nominal rise of the current to the rise equal to 200% of nominal value per minute. ACE.DOC
- 33 The lower limit of the parameter is 2 and upper limit is 300 sec " T FST RAMP xxx s " Default value 10s 4 BACK CORONA MODE : Displays number of back corona detection per hour. The working range is from 0.1-6 times per hour. Detection can be stopped by keying in 0 "BC MEANS x.x/hr" Default value 0. Non-Zero value of BC MEANS enables BC detection mode. PROCEDURE FOR CHANGE OF LEVEL 2 PARAMETERS : PASSWORD - By pressing this key, the display will show " ENTER PASSWORD " Keying in of illegal password will result in the following text " ILLEGAL PASSWORD " Keying in more digits than expected by the system for a parameter will indicate " TOO MANY DIGITS " After entering the relevant password, the parameter can be changed by simply keying in the new value followed by <ENTER/RESET>. Keying in the sequence for the level-2 parameter. KEY PASSWORD 2 2 2 ENTER/RESET DISPLAY INDICATION 'ENTER PASSWORD' * ** *** "T QUENCH xxxmS"
When changing another level 2 parameter within min, one can simply depress the parameter key, the new value and finally <ENTER/RESET>. The user has the freedom of changing the level 1 parameters even though, he is on level 2. One can return to level-1, Automatically, if the keyboard is not operated for 3 minutes. 12.6 LEVEL3 PARAMETERS There are no keys for these parameters, so they can be only displayed by keying the 2-digit code, after keying in <PASSWORD>. The level parameters correspond to factory adjustments. The following 2 digits code serves to display a corresponding level parameter. Depress <PASSWORD> 2 digit code and <ENTER/RESET> ACE.DOC
- 34 66 ENTER/RESET ( IDC nom ) This parameter serves to indicate the nominal current of the system.(Limit range 101-2001 mA) "IDC NOM xxxxmA" Default value 200mA. (ENTER/RESET) ( V DC - nom ) This parameter serves to indicate the nominal DC voltage of the system. Limits are from 45 - 150kV "VDC NOM xxxkV" Default value 150kV. (ENTER/RESET) ( V DC- max ) This is for setting the overvoltage limit. The limit is from 0 - (VDC nom -1). Exceeding the overvoltage limit for more than one sec will cut off the system. "VDC MAX xxxkV" Default value 149 kV. (ENTER/RESET) ( V DROP Ty1 ) This parameter serves to adjust the detection response of voltage drops in the precipitator. The range is from 3-20kV the parameter is to be considered as response adjustment rather than as voltage drop measured in absolute kV. 3 kV gives high and 20 kV gives low response. "V drop Ty1 xxkV" Default value 3kV. (ENTER/RESET) ( SPEC RE ) This parameter is called special reduction and serves as an additional set back for the Sparkovers, which time wise are closer than 1 sec. The range is from 0 - 200mA "SPEC RE xxxmA" Default value 20mA (ENTER/RESET): (BC CHECK TOL.) This parameter is used in Back carona detection while conforming back carona. This tolerance is used for comparing voltage. Min value 0.0%. Max. Value 5.0%. " BC CHK TOL x.x %. Default value is 0.0%. (ENTER/RESET) : ( BC MAX NEC ) This parameter is used in Back carona detection. This parameter sets upper limit of NEC in back carona detection. It can accept only values 1,3,5,7. "BC MAX. NEC x ". Default value 1. ENTER/RESET ( UNDER V DC ) This parameter is used to set under voltage limit. If output DC voltage remains below set limit for more than 30 sec, then unit will be switched OFF. Min Value is 0.0 kV. Max. Value is 25.0 kV. " UNDER VDC xxx kV" Default value is 9.0 kV (ENTER/RESET): ( BC - add ) This parameter is the allowance, given to the current set point relative to the last measuring stage, when the last back corona is detected. The allowance is adjustable from - 0 to 400 mA. "BC add xxxmA" Default value 250mA Actual allowance = BC add value less 200 Suppose for "BC add 0mA is entered then actual allowance = 0 - 200mA = - 200 mA. ACE.DOC
67
68
69
70
71
72
73
74
- 3575 (ENTER/RESET) (POWER) This parameter is read only parameter and shows instantaneous output power of the unit. Maximum value is 999.99 kW. 76 (ENTER/RESET) ( SPARKS T1 ) This read out shows the number of type 1 Sparkovers. Maximum value is 9999. Exceeding the maximum value, the counter will restart from 0. 77 (ENTER/RESET) ( SPARKS T2 ) This read out shows the number of type 2 Sparkover. Maximum value is 9999. Exceeding the maximum value, the counter will restart from 0. "SPARKS T2 xxxx " Default value 0 78 (ENTER/RESET) ( TEST LIMIT) This parameter serves to set percentage of conduction angle in test mode. " TEST LIMIT x x x % Default value 0 % 79 (ENTER/RESET) ( VDC START ) This parameter indicates to which the DC voltage is to be stepped up, just after the contactor is switched on. "VDC START xxkV" Default value 5kV Range is from 0 to 25 kV. 80 (ENTER/RESET) (PRST LIMIT ) This parameter displays the present current limit. This depends on back carona detection and energy control (NEC) Range is 0 mA to I DC nominal value. " PRST LIMIT xxx mA " Default value is I DC limit value. 81 (ENTER/RESET) ( dALFA res ) This parameter gives the firing angle for the reset firing before the actual main firing. Reset firing range is from 100-180. "dAlfa Res xxxdg" Default value 120. 82 (ENTER/RESET) ( ALFA res min ) This parameter gives the range upto, which the minimum reset firing angle is permissible. This parameter ranges from 90 to 180. AlfaResMin xxxdg Default value 180 C. 83 (ENTER/RESET) ( d ALFA Nec ) This parameter serves to increase the firing angle instantaneously while changing from higher NEC value to a lower value. Range is 0 to 40. d ALFA Nec xxx Default value 40 84 (ENTER/RESET) ( TEST MODE ON ) This parameter is used to enable/disable test mode by 1/0 respectively. ACE.DOC
- 36 85 (ENTER/RESET) (HINERGY) This parameter maintains minimum voltage level in case of energy control mode ("NEC>1"). It is the % of nominal voltage. If the output voltage goes below this level then additional pulses are generated between main firing to maintain this level. Minimum value is 0.0 %. " HINERGY " xx % Maximum value is 50 % Default value is 0 %. (ENTER/RESET) ( KwH ) This parameter shows output Energy and the value is store in the EEPROM so that during power OFF, data is not erased. This value can be reset by pressing simultaneously ENTER and 0 keys. Max. Value is 99999.9KWH. Exceeding the maximum value, the counter will restart from 0. (ENTER/RESET) ( R WAIT ) This parameter indicates delay pulses after Rapper bit is disabled before actual build up. Min value is 0 cycles. Maximum value is 99 cycles. " R WAIT x x x % " Default value 20 Cycles. 88 (ENTER/RESET) ( FIRING ) This parameter displays SCR firing angle in %. Minimum value is 0.0 %. " FIRING x x x % " Maximum value is 100%. Default value is 100%. (ENTER/RESET) ( VERSION ) This will shows the version of programs and date of modification. (ENTER/RESET) ( HT ON ) This parameter shows ON time duration of the unit in hour ( NODE ADDR) This parameter used to set address of the controller for serial communication in RS-485. The NODE ADDR should be unique in a system. This parameter range is 1 to 231. Default value 1 ( BAUD RATE ) This parameter is used set the communication speed of unit. Setting values are 1200,2400,4800,9600 and 19200 Default Value 9600.
86
87
89 90
CHANGE OF LEVEL PARAMETERS Change of level parameters requires pressing of keys in the following sequence. PASSWORD 'ENTER PASSWORD' 3 * 3 ** 3 *** RESET/ENTER "T QUENCH x x x mS. ACE.DOC
- 37 12.7 MISCELLANEOUS PROVISIONS INR / DCR : These two keys facilitate the user to view the desired parameters. By depressing the INR key the user is able to view the next parameter, in sequence after the currently displayed one. By depressing the DCR key the user is able to view the earlier parameter, that was displayed, before the currently displayed one. SPARK TEST Depression of this key simulates the spark action. RMT/LOCAL This key gives indication of controller status when LED ON indicates controller is in REMOTE MODE. 12.8 ANNUNCIATION : The alarm texts are flashed on occurrence of certain faults in the system. In case of several simultaneous alarms, only the latest alarm is flashed and hooter is switched ON. Fault is accepted and pressing ENTER/RESET key cuts OFF hooter. By pressing again ENTER/ RESET key next preset alarm is displayed. If the cause of alarm is removed, alarm text is removed. List Of Alarms Sr.No. 1 2 3 4 5 6 7 8 9 10 11 12.9 NAME High oil Pressure Ext. Overload TX Oil temp high TX Oil Temp high II. SCR temp high. Thermal overload. Process fault. Under voltage Over voltage Safety Line Con OFF TYPE Trippable Trippable Non Trippable Trippable Trippable Trippable Trippable Trippable Trippable Trippable Trippable
Starting sequence: ( Refer Fig. 1) Starting sequence begins when the main contactor is switched on (1). Thyristors are blocked for first 2 Sec (2) after that the voltage is raised to set value of parameters, 'VDC START' immediately (3). Then the DC current is raised from VDC start value with current rate of 200% per minute (100% corresponds to rated current) (4). If there is a Sparkover (5) during the starting sequence the control will react as described under automatic control & the rate of rise (6) is applied which corresponds to a calculated value based on IDC SET BACK, MAX SPARK RATE and actual Sparkover frequency. The rise is discontinued ACE.DOC
when current reaches the current limit (7).
- 38 The rate of rise is calculated internally in controller so that it will just reach the set Sparkover frequency i.e. MAX SPARK RATE. Key for setting SPARK RATE is MAX SPARK RATE and for set back is IDC SET BACK. The set back is adjustable between 5mA to 20% of IDC NOM. The Sparkover frequency is adjustable from 1-60 sparks per minute. Automatic Control: (Refer Fig. 2) The DC current is increased by the calculated rate of the rise until a Sparkover takes place or a current limit is reached. If the Sparkover is interpreted as type-1 Sparkover (8), the current set point is reduced by a value corresponding to the set back (9), current is then increased again by the same calculated rate of rise as before the Sparkover (10). If the Sparkover is interpreted as type II (11) the primary current is blocked (12) for a preset time (T QUENCH) adjustable between 5 -100mS. Current set point is reduced by the set back value (9) and then increased again by the rate of rise before the Sparkover. Definition of Type I & Type II Sparkovers: (Refer Fig.3, 4 & 5) Sparks are detected by sensing the precipitator voltage. The sparks are classified as type I or II according to their intensities. At voltage drops (12) of more than parameter "V drop TY1" a time measurement of 500 ms (13) is started for Type-I spark detection. If the voltage exceeds the limit before the time measurements finish, no Sparkover signal (14) is given otherwise type I (15) is signaled. If the voltage drops below the under voltage limit a time measurement of 20mS (17) is activated for type II. If the voltage rises above under voltage limit (16) before the time measurement finishes type I (18) is signaled, otherwise type II (19). T RECOVERY: (Refer Fig. 6) After Sparkover (21) the current is raised to reduced value (i.e. value before spark-over less setback) within set time (22) which is determined by the parameters (T RECOVERY). Then the current is increased at the calculated rate of rise. Rise time parameter (T RECOVERY) can be selected from 40mS upto 1S. During this period precipitator voltage is regulated and increased to a value corresponding to the mean voltage before Sparkover. At this point (23) there is changeover to current regulation and voltage rise to the value corresponding to the reduced current value takes place according to the shown function with (T RECOVERY) as parameter. When (T RECOVERY) has expired, the normal calculated rate of rise is proceeded with. Fast Ramp Mode (FRM): (Refer Fig.7) In case of fast process changes, especially with high Sparkover frequency and low rate of rise, current will reduce to very low value, it may take long time to reach normal value. In this case there is a need to reestablish the precipitator voltage quickly. This is done by parameter fast ramp (T FAST RAMP) being adjustable from 2 300S. This time is measured from last Sparkover and if it exceeds the set time (24), the rate of rise will change to 200% per min until the next Sparkover occurs (25), at this point the rate of rise is changed back to normal (26) or until current limit is reached. ACE.DOC
- 39 Spark-over limitation: (Refer Fig.7)

The Spark Rate (MAX SPARK RATE) is adjustable between 1 spark/min and 60 sparks/min. The sets Spark rate will not be reached if long quench time and rise times are selected. The spark rate limited to 60 sparks/min. To safeguard that this value is not exceed, a progressive current reduction has been included in the automatic control. This is achieved by adding special reduction to normal current setback. If the time interval between the sparks is shorter than 0.75 seconds. Then special reduction (0-200mA) is added (27) progressively until this condition exits. If time interval between two sparks is more than 0.75 seconds, the current is reduced by normal (28) set back value. When parameter spec. Reduction is set to 0 mA, this function is not active. Back Corona Detection: (Refer Fig.8) To overcome the deterioration in precipitator performance, the precipitator should be operated at the current level I BC (29) at which the negative slope just starts. The level of current I BC varies with the varying condition in the precipitator. HIRECT microprocessor controller ACE16, in back carona mode of operation, tracks the level of current I BC and automatically operates the precipitator at this level to avoid wasteful energy. Back corona detection can be activated from the control keyboard with key "BACK CARONA CONTROL". The detection can be activated from 0.1 to 6 times/hour. Detection is made inactive by inserting 0 times/hour. After activation the periodic back corona detection are made according to the following principle. The set point of the precipitator current is set for predetermined values which each are retained for 10 S. The set point may assume the following values during detection: 7,10,15,20,30,40,60 &100% of rated current. The set point cannot exceed the set current limit. The starting set point is found by going 3 steps towards lower values in the set point sequence than the actual value of the set point before the detection of back carona. In Fig.8, three steps down is 60-40-30% for 10 sec. And then increased to 40% for 10 sec and 60% for 10 sec. The mean precipitator voltage is measured during last 640ms of each retention. If 2 subsequent measurements have shown that the mean voltage is stationary or dropping with increasing current then values of set point is retained at last measurement i.e. if the mean voltage at 60% retention is equal to or less than the mean voltage at 40% retention then the value at 40% set point is retained. This value plus an allowance (30) is used as a new upper limit of current(BC limit) The allowance is variable from -200 to +200mA (parameter BC add) Voltage Alarms: If the precipitator voltage drops below the under voltage limit for more than 30Sec, under voltage alarm is displayed and unit is switched OFF. If the precipitator voltage exceeds set value of parameter UDC MAX for more than 1 Sec, overvoltage alarm is displayed and unit is switched OFF. Overvoltage can be adjusted from 0 kV to peak rated kV. 12.10 RELAY DRIVER CARD (CIRCUIT 4C-4682) The isolated signal from ACE-16 control card is brought on Relay Driver Card. This isolated signal is used to trigger triac TD1 to TD4. These triacs operate relays when ACE16 controller triggers them. 24V AC power supply is connected between pin 2 and pin No.14 of Relay driver card. One end of relay coil is connected to 24V AC power supply directly and other end of relay coil is connected to triacs of relay driver Card through ACE16 controller. Whenever triac is switched ON through ACE16 controller it switches ON the relay.
ACE.DOC
DATA SHEET
RAPPER DISTRIBUTION PANEL

MAKE QUANTITY NUMBER OF DIODES TERMINAL BLOCK INSTALLATION PANEL SIZE POWDER COATED M/S. DSA ELECTRO CONTROLS (P) LTD. 1 X 2 NOS. 96 NO. SINGLE DIODES (i.e. 48 DIODE SETS) SUITABLE TO CONNECT 2.5 mm CU. CABLE OUTDOOR 1300 (H) x 950 (L) x 300 (D) mm RAL 7032 SIEMENS GREY
SPECIFICATION
SUPPLIERS ADDRESS:
M/S. DSA ELECTRO CONTROLS (P) LTD, UNIT 48, 1ST B, RAJ INDUSTRIAL COMPLEX, MILITARY ROAD, HAROL, MUMBAI 400 059.
DATA SHEET
ELECTRODES
DESCRIPTION COLLECTING ELECTRODE
MAKE TOTAL NO.OF ELECTRODES APPLICATION TYPE MATERIAL OF CONSTRUCTION ELECTRODE THICKNESS HEIGHT X LENGTH SUSPENSION TYPE M/S. DEWAS METAL SECTIONS LIMITED 528 NOS. COLLECTING ELECTRODE FOR ESP MODIFIED G. PROFILE IS 513 / CRCA 1.25 MM 10000 X 450 MM BOLTED AT BOTH ENDS
SPECIFICATION
SUPPLIERS ADDRESS:
M/S. DEWAS METAL SECTIONS LIMITED, PLOT NO. AP866 (NEW NO.25), H-BLOCK, OFF: 12TH MAIN ROAD, ANNA NAGAR, CHENNAI - 600 004.
DATA SHEET
SPIKE ROD
MAKE QUANTITY APPLICATION TYPE MATERIAL M/S MANISHA CHEMICALS 504 NOS. DISCHARGE ELECTRODE FOR ESP SPIKE TUBE DIA 44.45 x 1.0, IS 1239 SPIKE DIA 2.7, 58 LG, IS 2062 ELECTRODE LENGTH NO. OF SPIKES PITCH OF SPIKES SUSPENSION TYPE 10950 MM 131 NOS 152 MM BOLT AT BOTH END
SPECIFICATION
SUPPLIERS ADDRESS:
M/s. MANISHA CHEMICALS. W-75, S - BLOCK, MIDC, BHOSARI, PUNE - 411 026.
DATA SHEET
EARTH DISCHARGE ROD

MAKE QUANTITY APPLICATION LENGTH M/S. NATIONAL ENGINEERS 10 X 2 NOS. EARTH DISCHARGE FOR ESP 1 MT WITH MOULDED RUBBER HANDLE GRIP AT ONE END AND BRASS TUBE AT OTHER END
SPECIFICATION
MATERIAL OF CONSTRUCTION
ROD CLAMP FLEXIBLE WIRE CABLE SOCKET GLASS FIBRE S.S. G.I. WIRE (2000 LG) COPPER TINNED CHROMIUM PLATED
SUPPLIERS ADDRESS:
M/s. NATIONAL ENGINEERS, DAKSHIN BARASAT STATION ROAD, N. KALIKAPORE (NEAR CHANDHI GANGA), P.O. DAKSIN BARASAT, 24, PARGANAS (S), WEST BENGAL.
DATA SHEET
PURGE AIR FILTER

MAKE QUANTITY APPLICATION TYPE SIZE IN MM MODEL NUMBER CAPACITY EFFICIENCY M/S. DYNA FILTERS PVT. LTD. 1 X 2 NOS FILTER FOR ESP PURGE AIR BLOWER HDPE 610 x 610 x 150 2 1600 CFM AT 6.5 mm W.G. PRESSURE DROP 90 % - 95 % DOWN TO 10 MICRON
SPECIFICATION
SUPPLIERS ADDRESS:
M/S. DYNA FILTERS PVT. LTD. NO. 98 / A5, INDUSTRIAL ESTATE, OPP. KIRLOSKAR PNEUMATICS , PUNE , MAHARASHTRA.
DATA SHEET
MECHANICAL SAFETY INTERLOCK

MAKE QUANTITY APPLICATION M/S PS POWER CONTROLS 1 X 2 NOS. MECHANICAL SAFETY INTERLOCKING ARRANGEMENT FOR 3 FIELD ESP
SPECIFICATION
SL. NO.
A
QTY. DESCRIPTION
ROTARY SWITCH TYPE LOCK WITH KEY INSCRIPTION OF R1, R2 & R3 (ELECTRO MECHANICAL LOCK)
(NOS)
3
B. .
BOLT LOCK TYPE FOR HT ISOLATOR WITHOUT INSCRIPTION OF R1, R2 & R3
KEY
WITH
C.
BOLT LOCK TYPE FOR HT ISOLATOR WITH KEY WITH INSCRIPTION OF E1, E2 & E3
D.
KEY EXCHANGE BOX 1 HAVING THREE FRONT LOCK WITHOUT KEY WITH INSCRIPTION OF E1, E2 & E3 AND TWO SIDE LOCKS WITH KEY WITH INSCRIPTION OF X
E.
KEY EXCHANGE BOX 2 HAVING 10 FRONT LOCK WITH KEY WITH INSCRIPTION OF C1 TO C4, IF, OF, PH, H1 TO H3 AND ONE SIDE LOCK WITHOUT KEY WITH INSCRIPTION OF X
F. G.
DOOR LOCK TYPE WITH MIN. 300 MM MS CHAIN WITHOUT KEY MS ENCLOSURE BOX FOR ALL KEY EXCHANGE BOXES
10 1
SUPPLIERS ADDRESS:
M/S. PS POWER CONTROLS, PORUR, CHENNAI 600 116.
DATA SHEET
HEATERS
MAKE M/S. RASHMI HEATERS PVT. LTD.
SPECIFICATION
SUPPORT INSULATOR HEATER:

QUANTITY APPLICATION 12 X 2 NOS. SUITABLE TO HEAT ENCLOSED SUPPORT INSULATOR FOR ESP RATED POWER RATED POWER SUPPLY THERMOSTAT 750 WATTS 415 V, 10%, 50 Hz 5%, SINGLE PHASE PROVIDED
HOPPER HEATER:
QUANTITY APPLICATION RATED POWER RATED POWER SUPPLY THERMOSTAT 12 X 2 NOS. TO HEAT ESP HOPPER 1000 WATTS 415 V, 10%, 50 Hz 5%, 2 PHASE PROVIDED
SUPPLIERS ADDRESS:
M/s. RASHMI HEATERS PVT. LTD, GATE NO.118/1, DHANORE, ALANDI-MARKAL ROAD TALKHED, PUNE 412 105.
DATA SHEET
HEATERS
MAKE M/s. ALCO HEATING COMPANY
SPECIFICATION
THERMOSTAT FOR SUPPORT INSULATOR:

QUANTITY APPLICATION 3 X 2 NOS.
TO CONTROL THE TEMPERATURE OF THE ABOVE INSULATOR
TYPE THERMOSTAT RANGE THERMOSTAT POWER SUPPLY CONTACT TYPE CONTACT RATING
ON / OFF 30 - 200C NIL POTENTIAL FREE (1 NO + 1 NC) 230 V AC, 5 AMPS
THERMOSTAT FOR HOPPER HEATER:

QUANTITY APPLICATION 1 X 2 NOS. TO CONTROL THETEMPERATURE OF THE HOPPER HEATER TYPE THERMOSTAT RANGE THERMOSTAT POWER SUPPLY CONTACT TYPE CONTACT RATING ON / OFF 30 - 200C NIL POTENTIAL FREE (1 NO + 1 NC) 230 V AC, 5 AMPS
SUPPLIERS ADDRESS:
M/s. ALCO HEATING CO., 32/39, TOLLYGUNGE CIRCULAR ROAD, KOLKATA - 700 053.
ESP MCC DRAWINGS

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CETHAR VE SSE LS LIMITED

PAGE NO. 002 003 008 015 020 024 028

SUB VENDORS MANUALS

ESP MCC DRAWINGS

CVL ELECTROSTATIC PRECIPITATORS

ESP PROJECT DESCRIPTION

WORK ORDER NUMBER

M/B/G/059 & M/B/G/060.

BG059 & BG060

SINGLE DRUM WATER TUBE BOILER (AFBC)

O & M MANUAL FOR ESP

CVL ELECTROSTATIC PRECIPITATORS

ESP TECHNICAL SPECIFICATION

GENERAL INFORMATION ESP

O & M MANUAL FOR ESP

CVL ELECTROSTATIC PRECIPITATORS

mm m2 mm m2/m3/ s m2 Nos Nos

457.5 504 Bolt at both end

Nos Nos Nos Kv Nos

RAPPING SYSTEM COLLECTING ELECTRODE

O & M MANUAL FOR ESP

CVL ELECTROSTATIC PRECIPITATORS

RAPPER CONTROLLER COLLECTING Type Timing Sequence Protection Indicating Instruments

Type Material Leakage Distance Maximum Flash Over Location

Rating Control Number Per Insulator Compartment

O & M MANUAL FOR ESP

CVL ELECTROSTATIC PRECIPITATORS

49.50 120 450 SCR Bridge Full-Wave

Type Hall-Wave / Full-Wave Rating - Each

Plate Thickness Design Pressure Construction Type Material

O & M MANUAL FOR ESP

CVL ELECTROSTATIC PRECIPITATORS

3 M3 mm Deg 35.82 5 IS 2062 GR. A 57

Type Size Height Above The Ground Level

Flanged mm mm 400 x 400 3500

Rating Number Per Hopper Control

1 3 Thermostat Perforated sheets IS 1079

Type Material Thickness Location mm

2 3 @ inlet & 1 @ outlet

O & M MANUAL FOR ESP

CVL ELECTROSTATIC PRECIPITATORS

ESP WORKING PRINCIPLE

CVL ELECTROSTATIC PRECIPITATORS

O & M MANUAL FOR ESP

CVL ELECTROSTATIC PRECIPITATORS

PARAMETERS AFFECTING ESP PERFORMANCE: -

RESISTIVITY OF DUST PARTICLE: -

O & M MANUAL FOR ESP

CVL ELECTROSTATIC PRECIPITATORS

FLUE GAS TEMPERATURE AT ESP INLET: -

CVL ELECTROSTATIC PRECIPITATORS

FLUE GAS VOLUME FLOW RATE THROUGH ESP: -

FLUE GAS COMPOSITION: -

PERCENTAGE OF MOISTURE IN FLUE GAS

O & M MANUAL FOR ESP

CVL ELECTROSTATIC PRECIPITATORS

PERCENTAGE OF SULPHUR OXIDES IN FLUE GAS

PERCENTAGE OF OXIDES OF SALTS IN FLUE GAS

PERCENTAGE OF ALKALI METALS IN FLUE GAS

FLUE GAS VELOCITY WITHIN ESP: -

O & M MANUAL FOR ESP

CVL ELECTROSTATIC PRECIPITATORS