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Commonly Found Problem
Contents
1. Mechanical Problems
2. Electrical Problems
OVERVIEW:
Commonly found Mechanical problems
1. Casing Leak
2. Gas Distribution System
6. Discharge Electrode
7. Insulators
Eroded GD screen
Detached GD screen
Detached GD screen
Deformed GD screen
Deformed GD screen
No baffle plate
Fallen hammers
Misaligned hammer
Missing hammer
Worn-out CE bearing
Worn-out DE hammer
Worn-out ratchet
Loose anvil
Missing hammer
Misaligned shaft
Aged hammer
Stainless
steel tip
Torn CE
Bent CE
Detached CE interlock
Worn-out CE interlock
Broken DE frame
Dust build up
Misaligned DE frame
Detached DE
Detached spacer
Detached DE
Detached DE bracket
Detached DE
Bent DE
7. Mechanical (Insulators)
Moisture on HV insulator
7. Mechanical (Insulators)
Overview:
Electrical Troubleshooting
Common Electrical Problems
Transformer Rectifier
Automatic Voltage Controller
SCR (Thyristor)
Other Units
Lead-in
Insulator
Open-Circuit Test:
Support Insulator
Expect
High kV
Zero mA
Short-Circuit Test:
Expect
Zero kV
High mA
Electrical Troubleshooting
Transformer Rectifier
Electrical Troubleshooting
Transformer Rectifier
Problems :
Oil Leak
Oil Contamination
Oil Level Low
Oil Temp. High
Oil Pressure High
Pri./Sec. Coil Fault
Rectifier Fault
Voltage Divider Fault
Bushing Contaminated
Bushing Crack
Feedback Signal Fault
TR retrofit or upgrade issues
Electrical Troubleshooting
Transformer Rectifier
MEGGER Test (Apply 1000Vdc)
Terminal
Reference
HV U
HV V
HV c2
Description
Rectifier
Casing
Grounding
HV(+) c1
HV() c1
HV GND
HV output
C1
Winding
C2
Voltage Divider
Electrical Troubleshooting
T/R: HV / LV Bushing
HV Bushing
Oil Leaks
HV Bushing
Contaminated
LV Bushing
Oil Leaks
Electrical Troubleshooting
T/R: HV Bushing & Voltage Divider
Contaminated
Bushing Cracks
Voltage Divider
Electrical Troubleshooting
T/R: Oil / Pressure / Temperature
Oil Level
Oil Contaminated
Electrical Troubleshooting
T/R: Internals
CLR
Rectifiers
Windings
Electrical Troubleshooting
T/R: Terminal Box
Feedback
Signals
LV Inputs
Electrical Troubleshooting
T/R Troubleshooting
TR Energization test
Test T/R set: switch T/R from other field
Electrical Troubleshooting
T/R Troubleshooting
TR Energization test
Test T/R set: switch T/R from other field
Electrical Troubleshooting
T/R Retrofit or Upgrade Considerations
Replace or Upgrade TR set Refer to TR name plate or ESP electrical
diagram for the TR specifications to be used as reference.
TR ratings
kV (secondary voltage)
mA (secondary current)
V (primary voltage)
A (primary current)
kVA
Operating frequency
Others
HV bushing orientation
TR dimensions
TR signal matching
Electrical Troubleshooting
T/R Retrofit or Upgrade Considerations
kV (secondary voltage) Rating
Rating
kV (secondary
voltage)
Ideal
70 80kVdc for
400mm gas
passage spacing
60 70kVdc for
300mm gas
passage spacing
Original TR
rating
Possible
Lower rating
than original
leads to weaker
field strength
Not allowed
Higher rating
than the kV
rating of ESP
insulators
Too high kV
rating (limited
by spark over
voltage)
Note:
Pay attention to kV rating whether it is indicated as peak, dc (average),
or RMS (effective) value.
Electrical Troubleshooting
T/R Retrofit or Upgrade Considerations
mA (secondary current) Rating
Rating
mA (secondary
current)
Ideal
Original TR
rating
Possible
Highest mA
attained during
operation given
good
mechanical
conditions
Lower rating
than original
leads to poor
dust charging
Not allowed
Too high mA
rating (space
charge effect
mA suppressed
by high dust
concentration)
Note:
Pay attention to mA rating whether it is indicated as peak, dc (average),
or RMS (effective) value.
Electrical Troubleshooting
T/R Retrofit or Upgrade Considerations
V (primary voltage) Rating
Rating
V (primary voltage)
Ideal
Original TR
rating
Possible
Higher rating
than original
but leads to
lower output kV
indicated on the
name plate of
the
replacement TR
(need to
compare
computed kV
output from the
original rating)
Not allowed
Lower rating
than original
Electrical Troubleshooting
T/R Retrofit or Upgrade Considerations
A (primary current) Rating
Rating
A (primary current)
Ideal
Original TR
rating
Possible
Lower rating
than original
but may lead to
lower mA
output
Not allowed
Higher rating
than original
Electrical Troubleshooting
T/R Retrofit or Upgrade Considerations
kVA Rating
Rating
kVA
Ideal
Original TR
rating
Possible
Lower rating
than original
leads to lower
output power
Higher rating
than original
(but must also
meet kV, mA, V,
and A ratings)
Not allowed
Higher rating
than original
(does not meet
kV, mA, V, and A
ratings)
Electrical Troubleshooting
T/R Retrofit or Upgrade Considerations
Operating frequency
Transformers 1 kVA and larger, rated at 60 Hz, should not be used on a
50 Hz service due to higher losses and resultant heat rise. However,
any 50 Hz transformer can operate on a 60 Hz service.
Others
HV bushing orientation side, top, or bottom.
TR dimensions may require the following:
HV duct modification
Extension, cutting, or replacement of HV bus bar
Fabrication of adapter flange from TR to HV duct
TR base adjustment
TR signal matching feedback resistor adjustment (or use original
signal board), ratings input to controller, and calibration.
Electrical Troubleshooting
Automatic Voltage Controller
Electrical Troubleshooting
Automatic Voltage Controller
Problems:
Electrical Troubleshooting
SCR
SCR
Electrical Troubleshooting
SCR
Problems:
1.Fault in one of the SCRs
2.Fault on SCR pair
3.Poor Insulation
4.Wrong Wiring
A
Electrical Troubleshooting
SCR: Poor Insulation
Electrical Troubleshooting
Others
Voltage
Divider
KV
mA
Electrical Troubleshooting
Others
Problems :
1. External Voltage Divider Fault
2. KV, mA, Vp, Ip Meters Fault
3. Improper Meter Calibration
4. Poor Grounding
5. Interconnection Wire/Cable Fault
Electrical Troubleshooting
Interconnection Wire/Cable Fault
HV Cable Breaks
Electrical Troubleshooting
Meter Fault
Electrical Troubleshooting
Meter Fault
Vp x Ip x Power Factor
= Vs x Is
Vp x Ip x Power Factor
Vs x Is
32 x 779 = 24,928 VA
Electrical Troubleshooting
Spark/Arc locations
Inside precipitator
Outside precipitator
Electrical Troubleshooting
Rapping motors
Overload trip: rapping system trips upon operation
Electrical Troubleshooting
Grounding
Electrical grounding
Electrical Troubleshooting
Grounding