“Electrostatic Precipitator ESP”Stage II, 2*660MWMPPGCL, Khandwa

PRESENTED BY:

VINAY VISHWAKARMA

ERECTION & COMMISSIONING ENGINEER

SHIVAM ENERGYTECH PVT. LTD.

Electrostatic Precipitator

Shri Singaji Thermal Power Project, 660*2MW, Stage II, MPPGCL, Khandwa, Madhya Pradesh

Introduction

➢A device that removes suspended dust particles from a gas or exhaust by applying a high-voltageelectrostatic charge and collecting the particles on charged plates.

➢ Electrostatic precipitation is a method of dust collection that uses electrostatic forces, and consists ofdischarge wires (negative plates) and collecting plates. (positive plates)

➢A high voltage is applied to the discharge wires to form an electrical field between the wires and thecollecting plates, and also ionizes the air around the discharge wires to supply ions.

➢ When air that contains an aerosol (dust, mist) flows between the collecting plates and the discharge wires,the aerosol particles in the air are charged by the ions.

➢ The Coulomb force caused by the electric field causes the charged particles to be collected on thecollecting plates, and the gas is purified.

Basic Diagram of ESP

Location of ESP

Step Up

Transformer TG Area Boiler ESP Chimney

Purpose of Installing➢The flue gases produced due to combustion of solid pulverized fuel in the furnace contain plenty of dustparticles.

➢ When a chimney releases these flue gases in the atmosphere without filtering these dust particles, theatmosphere may get polluted.

➢ Hence, these dust particles need to be removed from the flue gases as much as possible before these fluegases get discharged to the atmosphere.

➢By removing the dust particles from flue gases, we can control the air pollution.

➢Electrostatic precipitator does this work for a furnace system.

➢We install this device in the way of flue gases from the furnace to the chimney so that the device can filterthe flue gases before they enter the chimney.

WorkingThe working principle of the electrostatic precipitator is quite simple. It has two sets of electrodes one ispositive, and another is negative. The negative electrodes are in the form of rod or wire mesh. Positiveelectrodes are in the form of plates. The positive plates and negative electrodes are placed vertically in theelectrostatic precipitator alternatively one after another.

The negative electrodes are connected to a negative terminal of high voltage DC source, and positive platesare connected to the positive terminal of the DC source.

The positive terminal of the DC source may grounded to get stronger negativity in the negative electrodes.

To be continued…

To be continued…

Parts of ESP1. Collecting Electrodes (+ve Plate)

2. Discharge Electrodes (-ve Plate)

3. Transformer Rectifier Set (TR Set)

4. Support Insulator Heater (SIH)

5. Rapper Coil (CR, DR, GD)

6. Temperature Transmitter

7. Pressure Transmitter

8. Opacity Monitor/ Blower

9. Resistance Temperature Detector

10. Hopper Area

11. Hopper Heater (26 Module)

12. Low Level - Dust Level Indicator

13. High Level - Dust Level Indicator

14. Electronic Unit

15. Thermostat

Trestle- Cable Laying Way

Types of Tray1. Perforated Tray- 600mm, 300mm, 150mm, 100mm, 50mm.

2. Ladder Tray- 600mm, 300mm, 150mm, 100mm, 50mm.

Application

1. It gives mechanical strength to cable in every condition.

2. It gives path to cable for connection/termination.

3. The holes of tray gives natural cooling, water drainage, dust removing for cable. Perforated Tray Ladder Tray

Control Room - PMCC1. Source/ Power Transformer

2. Power cum Motor Control Centre (PMCC)

3. TR Panel Room

SOURCE/ POWER TRANSFORMER

Source/ Power Transformer➢This Power transformer is a step down type transformer which fed power to TR Set, PMCC Panel and then to all load which is used in ESPs.

➢Voltage level: 11KV to 440V.

➢Such load are Hopper Heater, Support Insulator Heater, Dust Level Indicator, Rapper Coil, Hoist, Opacity Blower, Lighting Induced Draught Fan and all machine which is working for ID fan.

➢Power is directly fed to PMCC panel through busbar duct.

POWER CUM MOTOR CONTROL CENTRE

Power cum Motor Control Centre

➢ It is an assembly from where the power of an equipment or machine is being controlled which is in centerlocation.

➢ It consists of Breaker, Busbar, Fuse, Indication Light, Relay, Contactor, Protection Transformer meteringequipment.

➢ Here Panel used 440V to feed load.

➢ It contains TR Panel feeder, SIH feeder, Hopper Heater feeder, Opacity Blower Power Supply, RapperPanel Power Supply, DLI feeder, ID fan feeder etc.

➢ It also having an arrangement of Bus-coupler to transfer power from one side to another to feed loadduring maintenance of Power Transformer.

Pre-commissioning activities Before charging a PMCC Panel some test have been followed by vendor/ client. They are as follows:

1. Megger Test on Busbar: By this test we are confirming that our Busbar is short/ open. If short then themegger reads 0Ωs and if it is open then megger reads above GΩ.

2. HiPot Test on Busbar (High Potential): By this test we are injecting 2KV (4-5 times of rated voltage) toBusbar by the help of Step-up Transformer and takes the value of current reading. If clamp meter readsbelow 50mA then the busbar is in healthy condition. It is also known as Dielectric Withstand test.

3. Relay Testing: In this test we check that relay is working properly or not. (Under Voltage Trip, OverCurrent Trip, Over Voltage Trip, Differential Protection).

4. Contact Resistance Meter (CRM): This test is especially important for contacts that carry large amountsof current (switchgear busbars) because higher contact resistance lead to lower current carrying capacity andhigher losses. Ductor testing is usually performed using a micro/ milli- ohmmeter or low ohmmeter.

#To ensure the busbars joints are giving minimum reading.

#Gradually increase the injected DC current to a specified current (e.g. 100A, 200A), then take the

micro-ohms reading.

To be continued…

Contact

CRM Test

Breaker AssemblyDistance between two Busbar

Megger & Hi-Pot Test CRM Test

Feeder given on PMCC PanelS. No FEEDER CAPACITY FUNCTION

1. To TR panel (Pass A) 400A To give supply to Transformer Rectifier Set for charging field/ electrode.

2. To SIH JB 25.5KW To give supply to support insulator heater for maintain the temperature of insulator.

3. To Electrical Hoist Motor Feeder 63A To give supply to hoist for loading & unloading of machine.

4. Power Supply to Rapper Panel 63A To give supply to rapper panel to run rapping system.

5. To hopper heater JB 23KW To give supply to hopper heater JB to increase the temperature of ash/ dust.

6. To ID fan MCC 250A To run ID fan for taking out minute particles in the air through chimney.

7. Raw power supply to EPMS 63A To run PLC for automation of an equipment located on remote area from control room.

8. Blower for opacity monitor 0.55KW To run opacity blower/ motor

9. 9:10A MCB O/G (7w+2S) 9:10A To give supply to DLI to operate.

10. LINE-A PT & Auxiliary

Equipment

50VA

11. Incomer – I 4000A

12. To Welding Receptacles for SWR.

Room

63A To give supply for doing welding in location site.

13. BUS-A PT & Auxiliary Equipment 50VA

14. Spare 23KW For future use

15. Spare 63A For future use

TR Panel Feeder

1. TR Panel feeder is only used to transfer power to

TR Panel from PMCC Panel.

2. It is operated, when user need maintenance in

TR Panel or during shut down.

3. It also protect the TR panel from heavy fault.

Hopper Heater Feeder1. The hopper heater is designed to preheat the hopper to prevent moisture condensate from

collecting ash in it during startup conditions.2. In addition, they maintain the hopper and fly ash at temperatures (50⁰C to 150⁰C) above the fluegas acid dew point during normal operating conditions.

To be continued…

Dust/ Ash Level Indicator (DLI/ ALI)1. DLI is a electronic device which is used to detect the ash level in hopper to protect the hopper from

overloading.

2. A change of Level of material in the hopper causes a change in dielectric which in turn causes a change

in admittance of this imperfect capacitor. An accurate measurement of this change affords an indirect

measure of the level of material in the tank.

DLI- HIGH AND LOW LOCATION

Support Insulator Heater Feeder

1. Electrostatic precipitators use electrostatic forces to

separate dust particles from exhaust gases in

industrial processes.

2. A number of high-voltage negative charged direct-

current discharge electrodes are placed between

positive charged collecting electrodes.

3. The contaminated gas passes through the passage

between the collecting electrodes, and the particles

become negative charged and adhere to the

collection electrodes.

4. Cylindrical or conical support insulators are used for

the suspension of the collecting electrodes and to

provide insulation to the ESP housing.

To be continued…

Rapper Panel & Rapper JB1. Rappers are used to transmit strong shearing forces to collecting plates in order to release deposited dust

particles.

2. Rapping is the process by which electrodes and particles are broken apart by vibrations from the rappers.

Often used in electrostatic precipitators, rappers relapse the caked on dust layer which then descends into a

hopper.

3. Number, size, and frequency of the rappers vary from system to system based upon the specific

characteristics of the dust being collected.

To be continued…

Cross- Sectional View of ESP

Ground Discharge Rapper

Funnel

Hopper

Gas Distribution System

Collecting Electrode

Support Insulator

Discharge Electrode

Rapping System

HV Transformer DC

Temperature Transmitter & Pressure Transmitter1. A pressure transducer, often called a pressure transmitter, is a transducer that converts pressure into an analog electrical signal. Although there are various types of pressure transducers, one of the most common is the strain-gauge base transducer.

2. A temperature transmitter is an electrical instrument that interfaces a temperature sensor (e.g. thermocouple, RTD, or thermistor) to a measurement or control device (e.g. PLC, DCS, PC, loop controller, data logger, display, recorder, etc.).

3. An RTD or Resistance Temperature Detector is a passive circuit element whose resistance increases with increasing temperature in a predictable manner.2

Opacity Monitor (OPM)

Overview and Equipment list

1. It is a dual-pass transmissometer configuredfor the measurement of opacity & dustconcentration within the flue gas.

2. The analyzer consists of a pair of stack-mounted transceivers designed to send andreceive a visible light beam across the stack inorder to obtain measurement of transmissivityof the stack gases, from which are calculatedvalues of opacity and dust concentration.

*Note: The dust calibration depends upon thesize and nature of the dust particles. It dustconcentration measured in mg/m3.

Equipment List

1. 2* transceiver with 10m of cable.

2. 2*site mounting flanges

3. 2* air purges

4. 2* ball valves

5. 1* Power Supply Unit (PSU)

6. 1* Signal Processor Unit (SPU)

7. 1* Data Display Unit (DDU)

Electrical Hoist

A hoist is a device used for lifting or lowering a load by means of a drum or lift-wheel around which rope or chain wraps.

It may be manually operated, electrically or pneumatically driven and may use chain, fiber or wire rope as its lifting medium.

EPMS/ PLC

TRANSFORMER RECTIFIER PANEL

Cross sectional View

Name Plate on TR panelELECTRONIC CONTROLLER

FOR H.V. RECTIFIER FOR ELECTROSTATIC PRECIPITATOR

MODEL ADOR CORONA

SERIAL NO. 15701-01-07-2018

CUSTOMER M/S L&T

PROJECT NO. 6678

ORDER REFERENCE NO. 01/1100/ 01334

RATED INPUT VOLTAGE 415 V AC 50 Hz

RATED INPUT CURRENT 302 AMPS

RATED OUTPUT VOLTAGE 95 KV (P) DC

RATED OUTPUT CURRENT 1300 mA DC

DATE OF MANUFACTURE JULY-2016

MADE IN INDIA

ADOR POWERTRON LIMITED. PUNE-411019 0551-2000-16-35/3

Need of TR Panel

The main purpose of installing TR Panel before TR Set is as follows:

1. Built in current limiting reactor to protect the electrical system from frequent short circuits in the field.

2. Extra heavy duty design suitable for 95 to 120 KV peak voltage, based on application requirement.

Inside TR Panel

Meter KV, V, mA, A

Meter Calibration card

Display

Emergency Stop Button

Local/ Remote Button

SCR

Mechanical Interlock CTs

TB 4

HRC Fuse 415V

Main Contactor

Fuse

DOC IV- Controller

Relay

Control Transformer

Auxiliary Contactor

Earthing Busbar

MCBs for Controller

Lamp Holder

Manual handle for ON/ OFF

Testing of a TR Panel/ TransformerBefore charging the Transformer firstly, we do some test on TR Panel and H.V. Transformer. The testare as follows:

1. Cable Continuity and Megger Value should not be less than 1GΩ. (Megger Voltage 5KV)

2. Transformer Primary and Secondary winding megger test. It should also not less than 1GΩ.

3. TR Panel test i.e. checking that panel giving rated output voltage. If not then controller may befaulty. This test is called “Lamp Load Test”. (Controller should be in Manual Mode)

4. If controller healthy then we do “Open Circuit Test” on a Transformer and observe the input andoutput voltage. (Rated input voltage is applied)

5. Then we do “Short Circuit Test” on a Transformer and observe the input and output current.(Rated input current is applied)

6. Then finally we charge the transformer and put under observation.

Problem & Troubleshooting on TR Panel S. No PROBLEM TROUBLESHOOTING REMARKS

1. INPUT VOLTAGE NOT INCREASING CONTROLLER ISSUE

2. INPUT CURRENT NOT INCREASING CT ISSUE

3. OUTPUT VOLTAGE NOT INCREASING FIELD SHORT

4. OUTPUT CURRENT NOT INCREASING SCR UNBALANCE, CT

ISSUE

5. INSTANTANEOUSLY CURRENT

INCREASING

SCR UNBALANCED

6. EXTERNAL ALARM 1 HOPPER HIGH LEVEL 1

7. EXTERNAL ALARM 2 HOPPER HIGH LEVEL 2

8. EXTERNAL ALARM 3 TR BOTTOM FLOAT/ OIL LEVEL LOW

TRIP/ PRV TRIP

9. EXTERNAL ALARM 4 TR TEMP. HIGH TRIP

10. MAIN CONTACTOR NOT PICK-UP LOOSE TERMINAL

Transformer Rectifier Set (TR Set)1. The T.R. is a static transformer which step up the voltage from 440V to 95KV and then converted the A.C.

voltage into D.C. voltage with the help of Bridge Thyristor.

2. The negative terminal of transformer is carried by Busbar (copper tube) to the field into discharge

electrode with the help of support insulator.

3. The positive terminal of output voltage is given to collecting electrode.

4. Both the electrodes are always in open condition. So there will be induce electric field between the

electrode.

5. That electric field energize the ash particles and attracted by the collecting electrode (positive terminal).

6. Then after sometime rapping system works, which removes the dust particles from electrode and get

collected to the hopper.

Nameplate on TR set

P.L.C. AND S.C.A.D.A.

Programmable Logical

Controller

Supervisory Control And Data

Acquisition

Programmable Logical Controller

➢ Its a hardware, which is directly in contact with field

instruments.

➢ It works according to the logic stored in PLC

Memory.

➢ It uses a language called “Relay Ladder Logic”.

➢ Positive Logic (most PLCs follow this convention)

True = logic 1 = input energized.

➢ False = logic 0 = input NOT energized

SCADA

1. Its a software, which shows the

output and feedback in Visual

manner, that PLC can't do.

2. A programmer design the animation

as per PLC programming and field

equipment position, then make

communication between SCADA and

PLC.

3. After successful communication

between SCADA and PLC we can

Visualize the operation which is

happen in field from Control Room.

Some SCADA image of ESP

EARTHING

Importance of Earthing

1. Overload Protection – In scenarios where excessive power surge occurs, a grounded system helpsimmensely. This simple form of surge protection can instantly save your electrical machine and devicesfrom getting fried by excessive electrical power, saving your data as well as equipment.

2. Voltage Stabilization – When it comes to calculating the right amount of power to be distributedbetween voltage sources, the earth provides that universal standard point of reference. Earthing takes theguesswork out of voltage stabilization, helping to ensure that no circuits overload or blow up.

3. Damage, Injury & Death Prevention – Blown fuses or a tripped circuit breakers are far more welcomethan electrical fires or shocks, which can pose serious safety hazards to people and property. Essentially,grounding protects against equipment, property and data loss, as well as injuries and fatalities.

DATASHEET OF CABLE S.No. EQUIPMENT SIZE CABLE TYPE

1 TRANSFORMER RECTIFIER 2C-300 SQ.MM ARMOURED

2 RAPPER PANEL 3C-25 SQ.MM ARMOURED

3 RAPPER COIL 2C-2.5 SQ.MM ARMOURED

4 OPACITY BLOWER 3C-6 SQ.MM ARMOURED

5 SUPPORT INSULATOR HEATER 3C-50 SQ.MM ARMOURED

6 HOPPER HEATER 3C-35 SQ.MM ARMOURED

7 DUST LEVEL INDICATOR 2C-6 SQ.MM ARMOURED

8 WELDING RECEPTICLES 3.5C-35 SQ.MM ARMOURED

9 EPMS/ PLC 2C-6 SQ.MM ARMOURED

10 ELECTRICAL HOIST 3C-16 SQ.MM ARMOURED

11 CONTROL CABLE 27C, 7C, 5C, 3C, 2C-2.5 SQ.MM ARMOURED

12 PAIR CABLECOMMUNICATION CABLE

16P, 8P, 4P, 2P-0.5 SQ.MM2P-0.35 SQ.MM

SCREENEDSCREENED

*NOTE: ABOVE CABLE HAD BEEN USED AS PER DRAWING & IT IS RECOMMENDED FOR THIS PLANT ONLY.

THANK YOU