Electrostatic Precipitator

Training Seminar
ESP Safety Operation and Maintenance

Overview
1. Safety Issue and Point of concern
2. Maintenance and Inspection

Safety Issues

Safety Issue and Point of Concern

Safety Issues
ZERO ACCIDENT
IS OUR GOAL

WORKING SAFELY
IS THE WAY

1. Hazardous environment in ESP

2. The right equipment
3. Safe activities
- Startup & Shutdown Procedure

Safety Issues
Hazardous

Condition

Confined space

Access difficultiesPartly openNatural ventilation is inadequate

Toxic gas

Electric shock hazard

Poor ventilationEnter from boilerDust of Chemical boiler

Power transmission errorWelding jobBroken wires

Elevated

Insufficient event spaceScaffolding opening

Heavy dust

Hopper dust build upWalkway dust build up

Fire disaster

Welding jobOxyacetylene cutting

Safety Issues
1.Hazardous Environment in ESP

Confined space

Mercury in dust

Welding job

Safety Issues
1.Hazardous Environment in ESP

Elevated

Hopper dust build up

Oxyacetylene cutting

Safety Issues
Gas testing
Ventilation and safety equipment
Personal protective equipment

Safety Issues

Ensure
[O2] > 18% , LEL<30% , H2S<10ppm ,
CO<35ppm , Temperature < 50C
Test the working atmosphere to determine
if it is safe for the proposed work

Gradually move inside the ESP

Safety Issues

ESP inside

Security cables

Hand rail inside ESP

Oxygen
breathing
apparatus

Emergency
respirators

Safety Issues

ESP Outside

Fan

Emergency Rescue

Grounding rod

Fire Extinguisher

First aid kit

Safety Issues

Safety helmet
Ear plugs
Earmuffs
Flashlight
Protective
working suit

Head light
Goggles
Mask
Harness
Gloves

(Hot work & Welding job)

Safety shoes

Safety Issues

Main T/R set grounding

switch
Control key box
Access doors

Ensure your own safety during maintenance & shut downs

Enforce safety procedures / start up and shutdown procedure
Energize system by authorized person / avoid human error

Safety Issues

Safety Issues

Main switch off

Manhole

Ground switch on

Key box

Ground on / TR Set

Safety Issues
Isolation
Shutdown the main breaker
Gauge reading are zero
Disconnect the connecting rod from T/R sets

36
24 0
1 0
2
00
TN
C

K50
25
V
0
TN
C

75

48
0

10
0

15
10 0
50 0
0
TN
C

m
A
0
0

60
40 0
20 0
TN
C

20
0

80
0

Safety Issues

Ground/Earth
Turn T/R Set Earth Switch to Grounding
position

Post signs
Attach the lock & tag, put working notice
Make sure all energy sources have been
shutdown

Safety Issues
Attendant

Stay in the area all time

Monitor the activities and condition
Understand hazardous environment
Recognize signs and symptoms of
exposure
Know rescue procedures

Attendance : Monitor

Safety Issues

A. Confirm that the system has been shut down

B. Press the Stop button on the control panel
power supply to the EP stop
C. Rapping system & ash handling system keep
running for 2~4hr
D. After 2~4hr turn off rapping system

Safety Issues

E. After rapping system is turned off 30min

then ash handling system is turned off
F. Turn off MCC control panel main breaker
G. Use interlock rom controller to switch the
grounding level from HV to grounding

ZERO

Safety Issues

Safety Issues

A. At least 4 8 hours before start-up, turn on the heaters

B. Turn on rapping system and ash handling system

C. Re-connect T/R sets with the fields, energize T/R set and
bring in gas flow into ESP

Safety Issues

D. Check the operating temperature

E. Check if the controller are working fine
F. Adjust the controller operating data if needed

Safety Issues

No tools/parts are left inside the EP

All personnel are to leave the area
Access doors are closed and locked

Safety Issues

ESP Control Panel

T/R Set Power off
Control Panel MCB Off & Interlock
Keys Off
Working Notice on Control Panel
HV Side Earthing Switch
Disconnect T/R HV to ESP
Earthing Switch to GND

Portable Earthing Probe

Earth the HV sideDE systemto
Ground

Rapping System
Stop Rapping System
Working Notice on Control Panel
Personal Protection Equipment
Goggle / Hamlet / Mask / Flash Light /
Gloves
Test on Oxygen Contain >18%
Inspection Completion, Leaving ESP
Confirm that all inspectors and
personnel are out of the ESP

Maintenance & Inspection

Maintenance and Inspection Planning

Maintenance & Inspection

Overview:
1.
2.

3.
4.

Maintenance& Inspection Planning

Mechanical Inspection
- Maintenance and Repair Works
- ESP internal Cleaning
Electrical Inspection
- Maintenance and Repair works
How much damage can be allowed ?

Maintenance & Inspection

(A) TR set operational data
(B) Control panel operational conditions
Daily
(C) Purge air and insulator heaters operational
(D) Status of ash handling system

Maintenance & Inspection

(A) The condition of TR and panel by seeing

Weekly

(B) The condition of access doors and gasket leakage

(C) Make sure the rapping system is working fine

Maintenance & Inspection

(A) The condition of purge air system (replace the filter)

Every
months

(B) The condition of hopper heater

(C) The hopper level

Maintenance & Inspection

Every
six
months

(A) Bolt and nut inspection and lubrication of access door

(B) Interlock box inspection and lubrication
(C) T/R set oil level and oil temperature

Maintenance & Inspection

(A) Ground boxes grounding impedance measurement
Grounding resistivity: lower than 5
Insulation resistance ofLow voltage wireHigher than1M
High voltage wireHigher than100M

(B) The condition of Rapping system

Hammer Bearing Shaft wear condition

Every
(C) Control panel clean and contact check
shutdown
(D) Access door gasket renew
(E) Control panel linkage and alarm
(F)EP casing leakage and corrosion

(G) The condition of ESP internal parts

CE, DE, GD screens, etc.

Maintenance & Inspection

2. Mechanical Inspection
(Tai & Chyun Mechanical Inspection Scope)
Casing Structure / duct works
Surface corrosion , Welding line Failure, Cladding & Insulation

Hoppers & Side Wall

Dust Build up, Corrosion

Access Doors (manholes)

Surface corrosion, Sealing

Maintenance & Inspection

2. Mechanical Inspection
(Tai & Chyun Mechanical Inspection Scope)
Collecting Electrodes
Dust Build up & Deformation, Cracking, Broken
Discharge Electrodes
Dust Build up, Broken, Slack

Rapping system
Wearing On Bearing, Shaft, Lifting Mechanism, Hammer, Anvil

Gas distribution screen

Dust Build up , Abrasion On Screens

Maintenance & Inspection

2. Mechanical Inspection
(Tai & Chyun Mechanical Inspection Scope)
Insulators
Dust Build up, Burn Mark , Water Mark ,Cracking

Heaters (purge air and ring heaters)

Heater Failure, Blower Failure, Thermostat Failure

Anti-sneak baffle plates

Welding Line Failure, Surface Abrasion, Dust Build up

Maintenance & Inspection

2. Mechanical Inspection
(Tai & Chyun Mechanical Inspection Scope)

ESP Inspection chart

Maintenance & Inspection

3. Electrical Inspection

Transformers
Physical appearance, HV bushing , Primary and secondary
terminal, Wiring connections, Oil leakage, Insulation and
grounding testing

Controller
Controller keypads, Controller board for TR set and rappers,
Wiring connections, SCR/Thyristor, Rapper controller,
Power breakers and contactors

Maintenance & Inspection

3. Electrical Inspection
Transformer Rectifier Set

Insulation Oil Refill / Change / Filtering/oil sampling

LV / HV Bushing Replacement
Grounding Switch Repair

Signal / Protection Circuit Repair / Replacement

T/R Set Replacement

Maintenance & Inspection

3. Electrical Inspection
Control Panel

Grounding Resistance Check

Thyristor (SCR) Replacement
AVC Controller and Keypad Replacement
Control Relays / Fuses / Power Supply TR Replacement
Network Check & Correction
Interface / IO Module / CAN Opener Check
Alarm / Lamp / Push Button Repair

Cable / Wire Connection & Termination Re-tighten

Interior Cleaning

Maintenance & Inspection

3. Electrical Inspection

Ring, Hopper and Purge Air Heaters

Resistance measurement, Terminal Connections,
Physical appearance

Rapping and Purge Air Heater Motors

Winding testing, Wiring connections, Fan and
blowers of purge air heaters, Appearance

Maintenance & Inspection

3. Electrical Inspection
(ESP Performance Test)
Open circuit test

VI curve

Short circuit test

Before start up

After start up

Collecting to discharge electrodes

testing

No load testing

Air load testing

VI curve

Maintenance & Inspection

3. Electrical Inspection (ESP Performance VI Curve)

*Normal Curve

Maintenance & Inspection

3. Electrical Inspection (ESP Performance VI Curve)
Description

kV

mA

Misalignment
(spark & arc)

Low

Low

Insulation
Problem

Low

High

DE Dust
build-up

High

Low

Normal

High

High

*Abnormal Curve

Maintenance & Inspection

4. How much damage can be allow ?
( Collecting Plates and Discharge Electrodes)

Is it time for CP / DE replacement ?

Maintenance & Inspection

4. How much damage can be allow ?
( Collecting Plates and Discharge Electrodes)
Space

CP~DE
150mm

Collecting
10mm
Plates

Discharge
Electrodes

10mm

CP~DE
200mm

Treatment Measures

15mm

For small qty, we could use reinforcement

plate for alignment.
The qty of the CEs has reached 10% of total in
1 field can planning replace CEs.

15mm

Cut the damage DE.

The qty of the DE has reached 10% can
planning replace DE.

Maintenance & Inspection

4. How much damage can be allowed ?
(Rapping System)

Is it time for rapping system replacement?

Maintenance & Inspection

4. How much damage can be allowed ?
(Rapping System)
1~3mm

4~6mm

7mm more

Mild wear

Moderate wear

Severe wear

Normal range of
values

Planned update

Update as soon
as possible

Maintenance & Inspection

4. How much damage can be allowed ?

Is it time for transformer replacement?

Maintenance & Inspection

4. How much damage can be allowed ?
(Transformer Rectifier)
Field
Position

Reference
Value

Description
Transformer / Rectifier Set

HV a1

>100 M Secondary to Primary

HV a2

>100 M Secondary to Primary

HV - c2

80-250 M

voltage divider

Rectifier

a1

T/R Casing
Grounding

a2
HV output

HV c1 (+)

1 M

Rectifier (Positive)
T/R Winding

HV c1 (-)

>100 M

Rectifier (Reverse)

HV-Ground

>100 M Secondary to Ground

c1

c2

Voltage
Divider

Your First Choice for Electrostatic Precipitator Services

END OF THIS SESSION