Zhejiang Feida Environmental Science & Technology Co.,Ltd.

Electrostatic Precipitator
Operation Manual

Address: 88 Wangyun Road, Zhuji City, Zhejiang Province, China

Tel: +86-575-87211558

Fax: +86-575-87383308

E-mail: ftd@feidaep.com

Post code: 311800

 Contents

1. Range of Application

2. Normative Reference

3. General Introduction

4. Principle of Operation

5. Briefing of Equipment

6. Installation, Inspection and Adjustment of Equipment

7. Safety Regulations of Equipment

8. Trial Run of Equipment

9. Operation Regulations of Equipment

10. Maintenance and Troubleshooting of Equipment

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 1 Range of Application

This manual defines the operating conditions, verification criteria, methods of

adjustment, trial run, operation, maintenance and troubleshooting, and safety points for

attention regarding electrostatic precipitator (ESP).

This manual is suitable for the commission, operation and maintenance of dry

plate-type horizontal F-model ESPs in the industries of thermal power generation,

metallurgy, paper-making, building materials, chemicals, etc. This manual can be used as

reference code for GP-model and ZH-model ESPs. For wet type and vertical ESPs, this

manual is not suitable.

2 Normative Reference

GB/T13931 Electrostatic Precipitator—Installation Manual

JB6407 Electrostatic Precipitator—Safety Technical Regulations of

Commissioning Operation and Maintenance

JB/T5910 Electrostatic Precipitator

Electrostatic Precipitator—Installation Manual

3 General Introduction

The ESP is a highly-efficient, energy-saving equipment for flue gas cleaning, having

merits of high collection efficiency, large gas volume to be treated, long life span and low

cost of maintenance. At present, as the requirements for environmental protection are

becoming more and more stringent, ESPs are used more widely. During the operation of

an ESP, its operation manual must be strictly followed. Any points that are not mentioned

in this manual should be handled as per the requirements in ESP drawings and

documents.

3.1 Model Designation

Our ESPs have their model numbers with the designation as follows, for example:

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 Note: The above model number can be simplified as:

3.2 Application Conditions of Conventional ESPs

Range of ESP application:

Gas volume: ≤6*106m3/h

Gas temperature: ≤400℃(＞250℃ is called high-temperature type)

Resistivity: 1×105Ω.cm～1×1014Ω.cm

Passage spacing: 250 mm ~ 600 mm

Applying pressure: - 4.4×104 Pa～0 Pa (Among which - 1.0×104 Pa～0 Pa

is called conventional type; - 4.0×104 Pa～- 0.1×104 Pa is

called high-pressure type)

Inlet dust loading: ≤100g/Nm3 (under standard conditions)

ESPs can treat flue gas that contains corrosives (called anticorrosive ESPs).

This manual does not apply to the treatment of flammable or explosive gases.

When the design operation conditions are beyond the application range of this

manual, the quality index should be specified in the product’s technical documents (e.g.

technical agreement).
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4 Principle of Operation

The principle of dust collection of ESP is as follows:

When passing through the high voltage electrostatic fields, dust particles in the gas

will be charged by colliding with positive ions, negative ions and electrons or in the ion

dispersion movement. The particles with electrons and ions will then move, under the

influence of the electric force, toward and later accumulate on the electrodes of opposite

polarity. By means of rapping, the layer of dust particles on the electrodes will be

dislodged into the bottom hoppers.

Practice shows that the higher the strength of electrostatic field, the more effective an

ESP will be, and that it is preferable to have an ESP operating with negative corona.

Therefore, our ESPs are designed in the structure of high voltage negative corona

electrodes with flowchart as follows:

5 Briefing of Equipment

Structurally an ESP is divided into two portions, electrical portion and mechanical

portion. Their main components and functions are described below.

5.1 Electrical Portion

The electrical portion consists of high voltage DC power source (including its control
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system) and low voltage control system.

5.1.1 Conventionally we use Model GGAJ02 high voltage power source. Designation of

the model is as follows:

Such a set of device usually includes high voltage transformer-rectifier, auto-control

cabinet and reactor, or of high impedance transformer-rectifier and auto-control cabinet.

This power source can automatically adjust the voltage applied to the electric field

according to the changes of gas conditions therein and can adjust the spark ratio in the

field to the optimum level that the highest results of dust collection can be achieved.

This power source is equipped with perfect interlocking protective system.

This device can be furnished with computer management system and host computer

according to the need of customer.

5.1.2 Low Voltage Control System and Its Functions:

a. Program control of collecting and emitting rapping;

b. Heating and heating temperature control of high voltage insulators;

c. Ash level check and alert control;

d. Control of ash discharge and ash conveying;

e. Control of safety interlock of doors, holes and cabinets;

f. Control of hopper electric heating;

g. Measurement and display of inlet and outlet gas temperature;

h. Setting of functions and parameters for LV system through host computer;

i. Display of integrated signals and alarm device.

Note: Above functions are selected according to requirements.

5.2 Mechanical Portion

This portion can be divided structurally into internals, casing and auxiliaries.
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5.2.1 Internals

5.2.1.1 Collecting System

The collecting system consists of suspension devices, collecting plates, shock bars,

etc. Collecting plates are shaped by steel coils 1.2 to 1.5 mm in thickness on special

rolling machines. At present, our company provides two kinds of collecting plates: 480C

type and 735 C type.

The surface of several collecting plates linked together must have good rigidity, and

its flatness should be kept within the specified range so as to assure the limited deviation

of distance between the collecting and emitting electrodes.

5.2.1.2 Emitting System

The emitting system consists of suspension devices, top horizontal beam, vertical

beam, upper, middle and lower frames, discharge wires, etc. The discharge wires are

manufactured by special equipment. Two types of discharge wires can be offered by our

plant, i. e. tubular barbed wire and spiral wire, both are ESP’s key parts.

Emitting suspension devices are used to support the whole emitting system from the

top girders and to connect with high voltage of negative polarity.

The function of the planar structure combined by vertical beam, top horizontal beam,

angle iron, etc. is to fix the upper, middle and lower frames and the emitting rapping

shafts.

The upper, middle and lower frames are the holders of discharge wires.

5.2.1.3 Correcting Rapping System

Collecting rapping system consists of drive, series of shafts, plain bearing, etc.

Normally it is driven from the ESP side.

5.2.1.4 Emitting rapping system

Emitting rapping system consists of drive, vertical shaft, major and minor pin wheels,

rapping shaft, plain bearing, etc. (for top-driven design) or of drive, series of shafts, plain

bearing, etc. (for side-drive design).

Rapping devices are important parts of ESPs. By rapping at regular intervals, dust

accumulated on both collecting plates and discharge wires is dislodged and falls into
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hoppers.

Both collecting and emitting rapping systems use tumbling hammers to carry out

side rapping.

Since the plain bearings are attached to the elements of emitting system at negative

high voltage, to isolate the high voltage, a porcelain shaft insulator is inserted serially

between two runs of the same emitting rapping shaft.

5.2.2 Casing

5.2.2.1 Inlet Nozzle

The inlet nozzle is the transition between the inlet flue duct and the ESP casing.

Inside the inlet nozzle there are 2 or 3 layers of gas distribution screens to make the

passing flue gas enter the ESP field as uniform as possible.

The gas flow will speed down when passing through the nozzle and some dust with

bigger size will accumulate by natural settlement on the distribution screens and the

nozzle. So some ESPs treating flue gas containing clogging dust are equipped with

distribution screen rapping devices (similar to collecting rapper).

5.2.2.2 Outlet Nozzle

The outlet nozzle lets the cleaned flue gas go into the exhaust flue duct. The

structure and shape of outlet nozzle also has something to do with gas distribution. Under

normal conditions, a row of outlet gas distribution screens (channeled plates with no

holes) is installed at the interface between the outlet nozzle and the casing.

5.2.2.3 Roofs

Roofs consist of inner roof and outer roof, of which the top girder is a key element as

it carries heavy loads from both the collecting and emitting systems. High voltage

electricity from the power source (no matter it lies on ESP top or on ground level) is fed in

through the top girder to the emitting system. To guarantee good insulating status of the

support insulators, heating devices are equipped within the insulator compartments to

maintain their dryness. Two types of heating can be adopted, electric heating or electric

heating plus hot-air heating.

5.2.2.4 Casing
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 The ESP casing is made up of pillars, side panels, end panels, pipe bracings, etc.

Casing, together with nozzles, roofs and hoppers, forms a sealed container.

On the side panels there are access doors.

5.2.2.5 Hopper and Hopper Ridge Beam

The hopper ridge beam is used to connect the hoppers to the casing

The hopper is a container for collecting dislodged dust. To prevent flue gas from

bypassing the hoppers, as will reduce the collection efficiency; anti-sneaking baffles are

installed in the hoppers. To guarantee that ash can flow down by itself in the hopper, the

hopper must have a right valley angle. To avoid condensation occurrence as the result of

dust temperature falling to below the dew point, heating is applied to the lower part of the

hopper (in some cases, all over the hopper).Two types of hopper heating are at choice:

electric heating or steam heating.

From the flange at the hopper bottom, pneumatic ash conveying system or gate

valve and discharge valve can be connected.

5.2.3 Auxiliaries

5.2.3.1 Stairs & platforms

These are provided for easy access to different locations at various levels so as to

carry out operation and maintenance.

5.2.3.2 Support Bearings

Support bearings are placed between the ESP casing and its support elements

(concrete pillars or steel columns). Besides supporting the ESP loading, the bearings

compensate displacement caused by thermal expansion, since the ESP is a hot body

when in operation while its support elements are cold.

Support bearings usually take the form of plate type compound material (friction pad)

slide bearings. But plane ball bearings are sometimes sued in ESPs of medium size or

smaller.

5.2.3.3 Thermal Insulation

To ensure the normal operation of an ESP and to prevent gas temperature from

dropping to below the dew point, thermal insulation should be laid over the ESP casing.
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 The principal function of the thermal insulation is to reduce heat exchange. By

applying thermal insulation, the minimum gas temperature must be guaranteed at a level

as high as 20 to 30℃ above the dew point.

The structural design of ESP thermal insulation should specify the kind of insulating

material, its thickness, type of lagging, respective quantities, etc.

5.2.3.4 Earthing

The ESP is operating under high voltage and normally with negative corona, which

means its casing and collecting system have the same potential. To protect high voltage

equipment and ensure personal safety, the ESP must be earthed reliably with

requirements as follows:

a. Resistance of the earthed grid should be less than 2 ohms all the year round;

b. The arrangement of the earthed grid should be such that the surroundings have

even voltage to ground.

6 Installation, Check and Adjustment of Equipment

6.1 The installation of the equipment should meet the requirements in “ESP’s Installation

Manual”.

6.2 Check and Adjustment of Equipment

Respective check and adjustment should be made to the electric and mechanical

portions after the equipment is erected but prior to its being put into operation.

6.2.1 Check and Adjustment of Mechanical Portion

6.2.1.1 Make second corrections of any deformed or bent collecting plates and discharge

wires within the electric fields to ensure that all the distances between opposite

electrodes are kept within the following deviations; for ESPs with plate height H≤7 m, this

deviation is ±7 mm and for H>7m, ±10 mm.

6.2.1.2 Make adjustments in the electric fields wherever the distance between emitting

system and other insulated parts is less than the distance between opposite electrodes.

6.2.1.3 Check all the bolts and nuts to see that they are properly tightened and welded

dead.

6.2.1.4 Check to see that the contact positions between the rapping hammers and anvils
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are exactly as required by the approved drawings, and that the shafts and hammers can

rotate freely.

6.2.1.5 Remove all foreign materials left within the electric fields.

6.2.1.6 Check to see that the motors for dampers, rapping, ash discharge, etc. have the

correct direction of revolution, that they can turn freely, that the chains are mounted with

proper tension and that all locations calling for lubrication have been oiled or greased. For

methods of commissioning, refer to Appendix B of “EPS’s Installation Manual”.

6.2.1.7 Check to see that all the insulators are mounted steady, under evenly distributed

loads and kept dry and clean.

6.2.1.8 Check to see that different parts of the ESP casing and all inspection doors are

properly sealed. Make gas-tightness tests as per Annex B of “EPS’s Installation Manual”

6.2.1.9 The rapping system is designed on the principles of improving the dust dislodging

effects, reducing dust re-entrainment, enhancing collection efficiency, lengthening the life

span of rapping elements etc. For details, refer to the ESP electric technical agreement of

the project. After a period of trial run, the rapping system is to be adjusted to its optimum

mode.

6.2.1.10 For the details of the ON-OFF system of ash discharge valve at hopper lower

end, refer to the ESP electric technical agreement. If pneumatic ash conveying system is

used, there is no need for ash discharge valve. In such a case, the hopper outlet is

connected direct to the ash transmitter, and the discharge of ash is carried out by means

of the inlet valve, which is controlled by the level indicator, on the transmitter.

6.2.1.11 Because the real actual gas distribution devices are designed and manufactured

on the acceptable results of gas distribution model tests, it is decided that no adjustment

test is to be made in site on the gas distribution devices.

6.2.2 Check and Adjustment of Electric Portion

6.2.2.1 Measure the ground resistance of the ESP proper and see that it is less than 2

ohms.

6.2.2.2 Use a 2500V mega meter to measure the insulation resistance of the high voltage

insulators and make sure it is larger than 500 megohms.

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6.2.2.3 The cable between the ESP casing and the positive terminal on the high voltage

transformer-rectifier should be in good order and firmly secured.

6.2.2.4 Use a 500V mega meter to measure the insulation resistance of all motors and

their cables and make sure it is not less than 0.5 megohms.

6.2.2.5 Check to see that the operating mechanism in the high voltage isolating

switchgear has high mobility and can be set to the exact positions.

6.2.2.6 Check to see that all wiring between different electric parts is correctly laid as per

approved product drawings.

6.2.2.7 Adjust the spark frequency in accordance with the electric conductivity of the flue

gas and the required collection efficiency.

Microprocessor-controlled thyristor transformer-rectifier has multiple functions such

as automatic tracing of sparks; therefore it will make the ESP operate under optimum

status, hence obtaining the realistic collection efficiency and having the lowest operating

cost.

6.2.2.8 The set value of the thermostat for insulator heating is normally 15-25℃ above

the gas dew point. The electric controllers are so required that the electric heaters are

energized when the temperature falls below the lower limit and de-energized when the

temperature exceeds the upper limit. Since the cover plate of the support insulator is so

designed that it allows a small amount of air to be sucked into the insulator to reduce its

contamination, and the cover plate is of high voltage, the temperature-measuring point is

far from the heat source but near to the cold air inlet. Therefore the indicated temperature

is lower, and this does not affect the insulator’s insulation.

6.2.2.9 Electric control circuits are to be adjusted according to the specified rapping and

ash discharge systems.

6.2.2.10 For various items in electric commissioning, such as LV control loop, HV control

loop, no-load voltage step-up test, cold trial run, hot load run, etc. refer to Annex B in the

“EPS’s Installation Manual” or the instructions provided by the manufacturers of electric

control systems.

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7 Safety Regulations of Equipment

ESP operators and those working temporarily in the ESP must have the general

knowledge of safety, and, as a special requirement, must abide by Standard JB6407.

There should be special personnel to be in charge of safety.

7.1 Personal Safety

7.1.1 The ESP is a high voltage installation, so special attention must be paid to personal

safety. Whenever the inlet part of high voltage T/R and the insulator compartment are in

service, any person must be away from them by a safe distance.

7.1.2 The inside of any electric field is a dangerous area of high voltage and no one is

allowed to enter during the operation of the ESP. All inspection doors must be interlocked

for safety.

7.1.3 Boards or signs bearing “Danger! High Voltage!” must be hung on each of the

control cubicles in the control room, on cable trays and trenches, on inspection doors and

on all high voltage equipment. They are not to be moved at random or approached by

non-operators.

7.1.4 The ESP is a high-altitude installation, so the stairs, platforms and handrails must

be reliably strong, and no accumulation of water or snow is allowed thereon. Also all the

walkways should be free of odds and ends or needless objects.

7.1.5 When performing inspection, maintenance, measurement at high altitude, no

matter it is outside the ESP casing or at high-located parts inside the ESP fields,

personnel must wear safety helmets and tie safety belts that have ropes connected or

can automatically lock.

7.1.6 The ESP is an installation operating at high temperature, high negative pressure

and under dusty condition, so no part of the human body is allowed to touch any hot part

of the ESP in operation. When the ESP is shut down for inspection/maintenance, the

doors should be spend to cool down the inside temperature to below 40℃ before people

can enter.

7.1.7 Should any door is left open during the operation of ESP, anyone near the door is

likely to be sucked in due to high negative pressure, resulting in bodily injures and even
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electric shock. Therefore, the doors must be interlocked.

7.1.8 Personnel to enter the ESP after its shut-down must follow the user’s safety

regulation.

7.1.9 To avoid human bodies from being infected by smoke and dust, wash the body and

protective overall after the construction is finished.

7.1.10 Wear a gas mask when you want to enter the ESP where there is too much dust

and smoke.

7.2 Safety Checks of Equipment

7.2.1 Make regular checks of the earthing cabling and other connections to see if they

have good electric conductivity and if other protective devices are in good order.

7.2.2 Make sure that all the locks on boxes for relays and switches are reliable, so that

irrelevant personnel can not open them easily.

7.2.3 The portable lamps for use in the ESP must be of safe voltage.

7.3 Safety Measures during T/R Maintenance

7.3.1 Make sure that the transformer-rectifier (T/R) has been de-energized with its safety

s witch located in OFF position and secured with a lock.

7.3.2 Check to see that all the switches on the control panel are in OFF positions.

7.3.3 A sign showing “T/R Under Repair”, no switching-in should be placed in an

eye-catching position in the front of the control panel.

7.3.4 Check to see if the earthing terminal is well earthed.

7.3.5 Earth the T/R high voltage parts with the earthing devices provided.

7.3.6 Make sure the above steps have all been executed before T/R maintenance.

7.4 Safety Measures for Maintenance inside ESP

7.4.1 A sign showing “People Inside ESP”, no switching-in should be placed in an

eye-catching position in the front of the control panel.

7.4.2 For maintenance inside the ESP, at least 2 persons are needed and one of them is

in charge of monitoring. Maintainers of ESP must be familiar with the design of the ESP

as well as the functions of its various parts and components. They should also know the

properties of the gas and the dust, their potential harms and the effective protective
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measures to be taken.

7.4.3 The shutdown of an ESP and personnel to enter it should follow the regulations

listed below:

a. Strictly follow the specifications set in 7.1 above.

b. Take the steps set in 7.3 above.

c. Turn off the safety switches of all rapping motors and the motors for ash

discharge valves and secure them with locks.

d. Turn off and earth the HV isolating switches close to the HV T/R sets, earth the

emitting system and secure with locks.

e. Turn the switches of ESP blower and I.D. fan to OFF position and secure them

with locks.

f. Shut off the dampers in ESP inlet and outlet flue ducts, turn off the damper

electric actuators and secure them with locks.

g. Open all the inspection (access) doors to ventilate the ESP inside and wait for

inside the temperature to drop to below 40℃ before people can enter. To

speed the process of cooling, the dampers in outlet flue ducts can be opened

and the I.D. fan turned on. But in such a case, the access doors must be

locked in their open positions to avoid sudden closing.

h. Maintainers entering the ESP should be aware of the risk of being scalded by

local not spots because of different degrees in cooling different parts and

components.

i. After entering the ESP, maintainers should first inspect to see if there is dust

accumulated somewhere. If there is, clean it to avoid mishaps. At the same time,

the causes for dust accumulation should be worked out.

j. When the maintenance is finished, maintainers should check their tools lest

some of them are left to impair ESP function.

8 Trial Run of Equipment

8.1 To ensure the reliability of operation of the ESP, before a new installation is put into

formal service after erection and commissioning or before an old installation is to resume
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operation after a long period of stoppage, a pre-operation trial run must be made.

8.2 Steps of ESP Pre-operation

8.2.1 An experienced engineer should be appointed to be the commander in chief of the

trial run. And the items to be checked should be planned and strict site records be kept.

To avoid damages caused during the operation by condensation of moisture in flue gas

or by not inspecting all the parts and components, the following checks should be made:

a. Check to confirm all the items listed in 6.2 above have been carried out with

acceptable results.

b. All the doors of thermal insulated boxes are locked.

c. Check to confirm that no one is inside the ESP or within other dangerous areas

of high voltage.

d. All the inspection doors are, closed and interlocked.

e. Check the open situation of flue duct dampers to ensure reliable operation both

manually and electrically.

f. Check the alarm functions on the test control panels to see if the tripping

functions are normal, sensible and reliable..

g. Check to see if the power net voltage is correct.

8.2.2 After inspection of all the pre-operation items of has been made with acceptable

results, perform the following operations:

a. Turn on the electric heaters for each insulator chamber.

b. Switch on the motors in turn for rapping, watch each link in operation and ash

discharge and keep them running for 30 minutes.

c. Detach the earthing devices from the high voltage parts to have an open circuit

between the emitting and collecting systems.

d. Turn on the HV isolating switches of the power units and lock them in the

operation positions.

8.2.3 Turn on the automatic voltage-adjusting system and observe the conditions of

no-load voltage step-up.

8.2.4 Keep records of the changes in primary voltage and current and secondary voltage
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and current. Since the no-load current has something to do with the temperature and

humidity of the air at the time of the trial run, pay attention to the capacity of the

equipment and values of voltage and current.

8.2.5 After the trial run is over, analyze and eliminate all the troubles occurred during the

trial run.

8.2.6 Plot the voltage-current characteristic curves for each electric field. On a sheet of

co-ordinate paper mark the values of voltage corresponding to a certain degree of

increase in current until the current reaches its rated value. Connecting the points

together will result in a curve, which is called voltage-current characteristic curve, and

which can be used as reference for the check of erection quality and for comparison with

later no-load curves of the same electric field each time after the ESP is overhauled.

8.2.7 Keep records of the loaded ESP’s primary voltage and current and secondary

voltage and current.

8.2.8 Using the same method as described above to plot the loaded ESP’s V-A curves

and analyze them.

8.2.9 Re-check the air leakage status of the ESP casing, inspection door, etc.

8.2.10 Shut the ESP down. (Refer to 9.5 below for details.)

8.2.11 Check the inside of the support insulator and the shaft insulator to see if they are

cracked or damaged.

8.2.12 Eliminate all the troubles occurred during the loaded trial run.

9 Operation Regulations of Equipment

9.1 The ESP should be operated and managed by professional people, who must have a

comprehensive knowledge of the equipment properties, operation requirements, safety

and maintenance, and who are familiar with THIS MANUAL. The owner of the ESP must

first have these people qualified by means of examination and check before they are to

operate and manage the ESP.

9.2 Before the start of ESP operation, make a final strict check of the equipment, keep

inspection records for each item and the records should be signed and approved by the

person in charge of field operation.

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9.3 Start-up of ESP

9.3.1 Make sure that pre-operation inspection is over, all the safety measures are taken

and all the operators are in place.

9.3.2 All the heaters have been turned on for at least 8 hours before the start-up of ESP,

so as to ensure the inside of all hoppers and various insulators (support insulators, shaft

insulators, etc) are dry, and to avoid any damage caused by electric creepage due to

condensation. Check all electric heaters to see if the current is correct.

9.3.3 Open all the dampers in inlet and outlet flue ducts (but with the exception of those in

inlet and outlet interconnecting sections).

9.3.4 Start the I.D. fan

9.3.5 Lead flue gas into the ESP to eliminate the moisture on various internals. This

period of warm-up depends on the temperature and humidity within each field and is

usually ended when the temperature at the outlet of the last field reaches a level higher

than the gas dew point. When oil is burning in the boiler never put the high voltage T/R

into operation.

9.3.6 Start the ash discharge system.

9.3.7 Start all the rapping devices.

9.3.8 Turn on all the functions of the rapping system. Set alarms, inter locking,

temperature detector and controller, ash level indicator, ash discharger, etc. all in a mode

of controllable operation.

9.3.9 When the fuel has changed from oil to coal and when the temperature in the ESP is

higher than the gas dew point, the ESP can be put into operation, but must be running

under a condition that the spark ratio is zero.

9.3.10 Start of the hot-air purging system: First turn on the electric heaters, after 5

minutes have passed, start the fan. For shutdown, turn off the fan first, then the heaters.

9.4 Operation process

9.4.1 There should be sufficient people on duty in the ESP control room. They should

make regular checks of the operation of the equipment. They should search for abnormal

phenomena, analyze the causes of troubles and solve them. For each work shift, beside
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being on duty in the control room at least two patrols should be made to check the

transformers and all rotary devices to see if they function properly and if the

speed-reducers are lubricated timely.

9.4.2 Main items to be inspected are as follows:

a. Check to see that the operating current of each heating system is correct.

b. Check all the indicator lamps and alarms to see if they function properly.

c. Check to see if the values of primary current A, primary voltage secondary

current mA and secondary voltage KV as indicated by the HV cabinets are

correct.

d. Check to see if the ash discharge system has any problem in discharging the

collected ash.

e. Regularly check to see if the rapping shafts turn normally and the hammers hit

properly (as can be heard from outside of ESP).

9.4.3 Observe and optimize the spark ratio, rapping sequence and ash discharge

program of each electric field until the satisfactory collection efficiency is obtained.

9.4.4 Persons on duty must keep intact records of the operation status of the equipment,

especially of the primary current and voltage and the secondary current and voltage

(normally to be recorded on a 2-hour base).

9.5 Shut-down of ESP

9.5.1 Temporary shut-down

a. Switch off all the I.D. fans. Wait for 3 to 5 minutes;

b. Switch off, in the order of electric fields, the high voltage power source to each

bus section and have the control cubicles locked;

c. Shut off all the dampers in both inlet and outlet flue ducts;

d. Keep in operation the rapping and heating systems;

e. At this point, people are not allowed to enter the ESP.

9.5.2 Long-term shut-down

a. Complete Steps a, b and c in 9.5.1 above;

b. Turn off the isolating switch to each high voltage bus section , turn it to the
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 earthing position and have it locked;

c. Turn off all systems of heating temperature measuring/controlling and ash level

controlling;

d. Keep in operation the rapping and ash discharge systems until all the smoke

and dust are removed from within the ESP;

e. Turn off the main power switch (with the exception of lighting);

9.6 For operation of the HV, LV control system and the host computer, refer to “Electric

Instructions”.

10. Maintenance and Troubleshooting of Equipment

To obtain the goal of the long-term reliable operation of ESP with required collection

efficiency. Professional personnel should be appointed do be is charge of ESP operation

and maintenance. These people must know the ESP’s design, principles, functions and

performance and are able to operate, to maintain and to troubleshoot the ESP.

During each shut-down of ESP, a general check should be made to clean its inside,

to correct the deformed plates and wires, to clear the insulators of dirt, to measure the

earth resistance and to eliminate all defects occurred during its previous operation

Normally the ESP is to undergo a minor overhaul once a year, items of which includes the

replacement of worn parts. Every third year (or based on the power plant’s overhaul

schedule) the ESP is to undergo a major overhaul, during which a spring-cleaning is

made inside the ESP and adjustment and replacement of defective or worn parts and

components are made. Moreover, lubricants are to be changed at regular intervals.

10.1 Routine checks and maintenance

10.1.1 After entering the ESP, first check to see if there is dust accumulated. If there is,

get rid of it.

10.1.2 Check the side panels, access doors and insulator compartments on top of ESP to

see if there are phenomena of air leakage, condensation, corrosion or dust accumulation,

if there are, eliminate them.

10.1.3 Check the motor temperatures, oil level in speed-reducers, shaft bearings and

rapping hammers to see if they are in good order and if the hammers hit on the correct
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locations. Lubricate the speed-reducers as per manufacturer’s manual.

10.1.4 Sometimes the gas distribution screens may have dust accumulations or

blockages somewhere due to low gas velocity thereon. Check and clean manually.

10.1.5 Check the emitting frames and discharge wires to ensure that they are not

deformed and that there is no dust deposit.

10.1.6 Check the collecting plates and shock bars to ensure that they are not bent and

that there is no dust deposit.

10.1.7 The support insulators support and isolate the emitting system. During the ESP’s

operation, these insulators will be usually covered with dust and dirt, which lead to

possible cracks resulting from high voltage breakdown. Clean both inside and outside of

the insulator and search for flaws by using a flashlight. To suck in hot air to reduce

insulator’s inside pollution, there should be two oblong holes of 5~10 mm in the

insulator’s cover plate.

10.1.8 Check and clean the shaft insulators in emitting rapping shafts, if there are flaws,

change the insulator.

10.1.9 With reference to the manufacturer’s manual, check the T/R sets to see if the

functions of the HV isolating switches, relays, heaters, instruments for temperature

measuring and controlling, alarms, earthing devices, etc. are normal. Eliminate the

defaults if there are any.

10.2 Warnings

10.2.1 Take strict precautions against sever dust build-ups in electric fields:
Excessive dust build-ups inside the electric field are usually caused by failure in the
dust conveying system, insufficient conveying capacity, the failure of hopper heater or
poor hopper insulation. In such cases, dust collected by the hopper will adhere or “bridge”
and it can’t be discharged in time, resulting in huge amount of dust piling in the hopper.
When the accumulated dust reaches the electrodes, there will be short-circuits formed in
the electric field, causing the failure of collecting rapping system, making collecting
electrodes drop off their hooks, and even deforming the emitting frames. As a result, the
electric field is out of function, and severe consequences occur. What calls for high
attention is the condition that, when the electric field is out of service, the boiler is still in
operation and there is still abundant dust falling down by natural settlement. Therefore, if
20
the problem of hopper’s over storage of dust is not solved in time, there will be
irreversible damages to the ESP. Emergent dust discharge measures must be taken to
stop further damages to the ESP.

These measures include:

a. Take strict precautions against over-storage of dust in the hoppers. When there
is alarm for hopper high level, the actual operation condition of the dust
conveying system must be checked, and necessary measures taken to ensure
smooth conveying so that the dust level in the hopper can be lowered, and the
high level alarm, deactivated.

b. When the dust accumulation exceeds the upper level of the hopper and trips
and electric field, emergent dust discharging measures should be taken within
the shortest time. Within 3 hours, the dust should be removed and within 8
hours, the dust level should be lowered to below the hopper’s upper opening,
so that the operation of the affected electric field can resume.

c. If the over-storage of dust can’t be eliminated within 8 hours, mandatory

measures must be taken, such as: cutting a hole in the hopper’s lower part,
opening the hand hole, etc. to discharge the dust manually.

d. If, within 48 hours, all the measures fail to bring the dust level lower than the
hopper’s upper opening and the electric field is still in a tripped state, the ESP,
the boiler must be shut down so that their reliability and safety are secured.
Otherwise, there will be severe consequences.

e. Personal safety is most important in manual dust discharging, especially

when there is a dust bridge in the hopper. When acted by other foreign
forces, the dust bridge will collapse suddenly, hence scalding or other
mishaps.

10.2.2 None is allowed to enter the ESP without safety measures.

10.2.3 Non-professional personnel are allowed to enter the top of the ESP
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 Analyses and treatment of comprehensive defaults

No. Defaults Possible Causes Remedies

1. 1 Secondary working 1) HV parts may be earthed by foreign matters. 1) Check the field or insulator
current is big. Secondary 2)High resistivity dust or gas nature changes the chamber to remove foreign matter.
voltage won’t rise and corona voltage. 2) Change the coal type or use gas
there is no spark. 3)Soft breakdown of HV sampling loop in control conditioning.
cabinet or emitting tube, or the hands of some 3) Repair the HV loop and replace
meters get stuck. elements.
4)Soft breakdown of emitting tube in parallel with the 4) Replace elements.
HV sampling resistor in the T/R
2. 2 Secondary current (1)
is 1) Dirty insulator, or insulator heater failure and poor 1) Repair or change the heating
normal or too big. thermal insulation resulting in surface element, clean the insulator. When
Secondary voltage won’t condensation, reduced insulation function and gas temperature is lower than
rise electric creepage. Or gas temperature in field is actual dew point, the equipment
lower than actual dew point, resulting in can’t be put into operation
condensation on insulator, hence electric 2) Check and adjust the voltage
creepage. distance.
(2) 2) Severe dust deposit on both electrodes, causing 3) Check and adjust the voltage
change in distance between them. distance.
(3) 3) Installed deviation in voltage distance is big. 4) Repair by welding at the leaks in
(4) 4) Poor welding in casing, poor sealing of access casing. Tightly close the access
doors, resulting in impacts by cold air, doors.
condensation and deformation of both electrodes 5) Check the fixing device of both
and smaller voltage distance. electrodes.
(5) 5) Both electrodes sway, causing severe flashovers 6) Dredge the ash discharge and
under low voltage. conveying systems, remove ash
(6) 6) Hopper is full of dust, which is close to the emitting deposits, check hopper heaters
system, causing reduced isolating between both and not allow hopper overstorage.
electrodes. 7) Check and repair the T/R
(7) 7) Low voltage from HV T/R 8) Check and repair the system’s
(8) 8)Big voltage drop in other parts of the loop(e.g. poor loop
earthing)

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3. 3 Severe flashovers,
(9) Too much dust is stored in the hopper and it rises See Item 6, c and d in Clause 10.2.1
resulting in tripped field. above the hopper upper opening, even reaches both above.
electrodes, resulting in reduced isolating property
between them.

4. Se4 Secondary current changes Dust is deposited on some electrode, where the Remove the dust deposit.
irreirregularly voltage dis distance is smaller, causing sparkovers

5. 5 Secondary current
Ds The remaining part of a broken emitting wire sway Replace the broken wire.
changes periodically

6. 6 There is secondary D 1) Excessive dust loading causing corona blockage 1) Improve the technological process
voltage but no or very little 2) Severe dust deposits on collecting and emitting to reduce dust loading in gas.
secondary current. systems. 2) Intensify rapping and remove dust
3) High ground resistance and poor high voltage deposits.
loop. 3) Reduce the ground resistance to
4) Broken circuit in the measuring loop of ampere the specified value.
meter in HV loop. 4) Rectify the broken circuit.
5) Poor contacts between HV outlet and electric field 5) Check the connections and make
6) Point of millimeter gets Stuck. them in full contact.
6) Repair the meter.
7. 7 Abnormally plentiful sparks 1) Leaks in access doors let wet air in. 1) Take corresponding measures
2) Poor contact in T/R secondary side or open circuit 2) Find the real cause and repair or
in diode of rectifing bridge. replace.
3) Uneven gas flow distribution 3) Replace the gas distributors.
4) Voltage distance turns smaller. 4) Adjust the voltage distance.
5) Hopper is full of dust. Or there are areas of dust 5) Remove the dust deposits.
deposits and dust can’t drop smoothly. 6) Replace the damping resistor.
6) Damping resistor is broken an causes electric
discharge
8. 8 Normal primary and 1) Too big voltage distance. 1) Adjust it,
secondary current and 2) Uneven gas distribution, gas screens blocked by 2) Remove the dust, OR replace the
voltage, but the collection dust. gas screens.
23
 efficiency is low. 3) Excessive air in leakage resulting in changes in 3) Make repair welds where there is
operation conditions. Increase of gas velocity, air in leakage.
decrease of temperature, weak charging 4) Condition the gas quality and
possibility of dust particles, etc. adjust the work point.
4) High resistivity of dust, backcorona may exist, 5) Adjust the parameters.
slow charge neutralization in dust layers on 6) Collection efficiency is be
electrodes and rapping unable to dislodge them calculated by using correction
due to significant adhesiveness. curves to the actual operation
5) Unreasonable setting of control parameters. conditions
6) Conditions of gas entering the ESP do not agree 7) Repair as needed, if rapping is not
with the original ones resulting in changes of sufficient, replace with heavier
operation conditions. hammers.
7) Mechanical problems such as abnormal rapper. 8) Check to solve the problem.
8) Gas flow by-passes due to fallen gas baffles in
hoppers.
9. 9 Stuck ash discharge 1) Hammer dropped Shut down the equipment to repair.
device, OR tripped safety 2) Foreing matter in discharge mechanism.
device 3) Broken chain in case a drag chain conveyer is
used
10 Failure in control, alarming 1) Thyristor is broken down. Find the causes before repair or
tripped 2) Thyristor’s initial wire is at a wrong position or the replacement.
plugging leg is short-circuited.
3) Primary side of T/R is earthed or short-circuited.
Or before the secondary side sampling loop there
is a short circuit. Or the negative HV is earthed. Or
there is a short circuit in current and voltage
sampling loop.
11 Thyristor’s outlet can’t be 1) Thyristor is broken down. 1) Replace it.
controlled 2) Feedback quantities disappear 2) Check relevant elements and loops
Sampling resistor row is damages. 3) Adjust the parameters.
3) Wrong setting of parameters.
12 Abnormal operation of 1) Safety interlocking is not in place 1) Check to see if the access doors
control loop and main loop 2) Interlocking for HV isolating switch is not in place and cabinet doors are closed
3) Broken wire in switching-in coil and loop. properly.
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13 No lamp indication on
control panel when it is
energized.
14 When the voltage is being
adjusted, no indication is
on the control meters
15 There is signal on
flashover indicator but
other meters on the
control panel do not act
16 After a flashover, the
secondary voltage does
not rise by its own but
initiates an alarm.
17 During loaded voltage
step-up, there is normal
voltage indication but
current is zero.
18 During voltage step-up,
primary voltage can be
adjusted properly, but
secondary voltage
appears and disappears
4) Poor contact in auxiliary switch 2) Check the switch to see if it is
properly interlocked.
3) Replace the coil and check the
wiring.
4) Check and repair it.
1) Poor contact in loops and between elements. 1) Check every element and loop for
2) Burnt bulbs wiring
3) Burnt fuse 2) Replace them
3) Replace it.
1) There are faults in the meters. 1) Repair and calibrate the meters
2) There is no trigger output pulse. 2) Use an oscilloscope to determine
3) Broken quick-break fuse. the number and width of the
4) Open circuit in thyristor element. pulses
5) AC & DC sampling loops broken 3) Replace
6) Poor contact of change-over switch in AC 4) Change
voltmeter 5) Check the secondary wiring
6) Check the switch contacts.
1) There is foreign interference 1) Check the earthing of the shield
2) Signal transfer is blocked by flashover and some 2) Add a by-path and replace
elements are damaged. damaged elements.
1) The first blocking pulse is too wide upon the 1) Change the parameter to adjust
flashover the pulse width.
2) The given value of the rising ratio of voltage 2) Increase the given voltage
+△v/△t is too small
1) Open circuit in current sampling loop. 1) Check the secondary wiring
2) Broken wire in ammeter 2) Measure the voltage.
1) Open circuit and false soldering points in T/R 1) Lift the T/R core to check and
secondary coil and silicon stack. eliminate the defaults.
2) Insufficient safety distance from HV down-lead to 2) Check and reconnect the HV
ESP casing. down-lead.
3) Open circuit in DC component voltage sampling 3) Lift the T/R core to check and
25
 alternatively and is loop. repair.
accompanied by sound of
electric discharge.
19 Tripping of oil pressure Breakdown or short-circuit in T/R secondary coil or Lift the T/R core to check and replace
alarm and ozone smell silicon stack. the damaged part.
from T/R
20 Tripping and alarm T/R oil level is lower than the lower limit. Troubleshoot and add oil to T/R up to
activated by oil level signal the suitable level.
21 Tripping of oil pressure There is gas in the gas relay. Open the discharge valve to get rid of
alarm the gas.

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10.4 Replacement of spiral wires and support insulators

10.4.1 Replacement of spiral discharge wires

Discharge wires are the heart part of an ESP. They set off electric energy to the gas, and

function in an adverse environment. Under high voltage conditions there would be flashovers

and arcs, each of which is a kind of corrosion by electric spark to the discharge wires. For spiral

wires, when they are rapped, they will vibrate in the way strings on a musical instrument will do.

Therefore, after long service the spiral wires may break due to fatigue (but the rate of breakage

is very low). If a spiral wire breaks, it will lean against one of the adjacent collecting plates and

short-circuit will happen, resulting in the shut-down of the related bus section.

During the replacement of spiral wires, in addition to the five points of attention as

described in 10.2.1 above, follow the steps below:

a. Put the upper end hook of the spiral wire into the hanger ring.

b. Connect the other end hook of the wire to the special stretching tool and pull down

gently by holding the rope on the tool. By doing so, be sure to let the spiral wire turn

freely. When the wire is stretched to a point of 200 mm to 300 mm away from the lower

hanger ring, manage to put the hook into the ring by hand. Special care should be taken

to the following:

1) Should a spiral wire be stretched beyond its length as it is hung, it should be discarded.

It is never allowed to squeeze/compress an overstretched wire to its “original” status for

re-use.

2) Do not pull the wire directly by hand as this will cause accumulation of inner stress in the

wire, resulting in easy breakage.

3) The spiral wire must be hung between the two corresponding hanger rings of a support

frame.

10.4.2 Replacement of broken support insulator (see the sketch below)

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Use a straight ruler to measure the distances from the tie rod to the compartment top cover and

the walls a, b and c, and have them recorded (or written on walls).

10.4.2.1 Dismounting

a. Remove the top cover of the insulator compartment.

b. Insert the lifting tool through the bushing and hook on to the upper support beam of

the emitting frame;

c. Turn the nut on the lifting tool to raise the emitting frame to let loose the support

insulator. Unscrew the nut on the tie rod, remove the top washer and dismount the

broken insulator.

10.4.2.2 Mounting

a. Check and clean the top and bottom washers of the insulator;

b. Check to see if the packing material is in good order and in place;

c. Mount the new insulator in the reverse order of dismounting;

d. Check the location of the tie-rod, be sure that it is in the exact position as it was

before the replacement of insulator.

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