You are on page 1of 58

Electrostatic Precipitator

Training Seminar
Commonly Found Problem

Contents
1. Mechanical Problems
2. Electrical Problems

OVERVIEW:
Commonly found Mechanical problems
1. Casing Leak
2. Gas Distribution System

3. Anti-Sneakage Baffle Plate


4. Rapping System
5. Collecting Plate

6. Discharge Electrode
7. Insulators

1. Mechanical (Casing Leak)

Inlet nozzle leak

Inlet nozzle leak

Dust build-up in inlet duct

Dust build-up in inlet duct

1. Mechanical (Casing Leak)

Corroded inlet nozzles

Expansion joint leak

Expansion joint leak

Expansion joint leak

1. Mechanical (Casing Leak)

Outlet nozzles leak

Roof casing leak

Roof casing leak

Hopper crotch leak

1. Mechanical (Casing Leak)

Wall casing leak

Wall casing leak

Wall casing leak

Access door leak

2. Mechanical (Gas Distribution System)

Eroded GD screen

Dust build-up on GD screen

Detached GD screen

Detached GD screen

2. Mechanical (Gas Distribution System)

Deformed GD screen

Deformed GD screen

Broken turning vane

Broken turning vane

3. Mechanical (Anti-Sneakage Baffle Plate)

No baffle plate

Big gap baffle plate

Deformed baffle plate

Detached baffle plate

4. Mechanical (Rapping System)

Worn out hammer arm

Fallen hammers

Misaligned hammer

Missing hammer

1. Mechanical (Rapping System)

Worn-out CE bearing

Bent rapping shaft

Worn-out DE hammer

Worn-out ratchet

4. Mechanical (Rapping System)

Worn out bearing

Worn out bearing

Worn out pin wheel

Loose anvil

4. Mechanical (Rapping System)

Worn out bolt/pin

Broken rapping insulator

Missing hammer

Misaligned shaft

4. Mechanical (Rapping System)

Worn out support

Aged hammer

4. Mechanical (Rapping System)

Stainless
steel tip

Plunger height check

Worn out stainless steel tip causes malfunction


of MIGI rapper due to magnetization.

4. Mechanical (Rapping System)

Leakage from gland packing

Broken rapping insulator for


MIGI rapper

Leakage from gland packing

5. Mechanical (Collecting Electrode)


Cracked CE

Torn CE

Bent CE

Eroded CE due to manhole


leakage

Arc cut due to broken frame

5. Mechanical (Collecting Electrode)

Detached CE interlock

Missing bolts on CE suspension


beams

Worn-out CE interlock

6. Mechanical (Discharge Electrode)

Broken DE frame

Arc cut on DE frame

Dust build up

Misaligned DE frame

6. Mechanical (Discharge Electrode)

Detached DE

Detached spacer

Detached DE

Detached DE bracket

Detached DE

Bent DE

7. Mechanical (Insulators)

Dusty support insulator

Dusty lead-in insulator

Dusty rapping insulator

Moisture on HV insulator

7. Mechanical (Insulators)

Water around support insulator

Cracked support insulator

Broken lead-in insulator

Broken lead-in insulator

Commonly Found Electrical Problems

Overview:
Electrical Troubleshooting
Common Electrical Problems

Transformer Rectifier
Automatic Voltage Controller
SCR (Thyristor)
Other Units

Open Circuit / Short Circuit Test


T/R Set
Power
Supply

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

Tai & Chyun Associates Industries, Inc.

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

>100 M Secondary to Primary

HV V

>100 M Secondary to Primary

HV c2

Transformer / Rectifier Set

Description

Rectifier

Casing
Grounding

80-250 M Voltage Divider

HV(+) c1

< 1.0 M Rectifier (Forward)

HV() c1

>100 M Rectifier (Reverse)

HV GND

>200 M Secondary to Ground

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 Pressure / Temp.

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

Connect adjacent mechanical


fields and disconnect the
electrical connection from the
T/R set. Use the known to be
working T/R set.

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:

1. EPROM (Data Storage)


2. Keypad Fault / Lockup
3. Display Fault / Obscure Display
4. Mainboard, Firing Board Fault
5. Improper Wiring (Replacement)

6. Improper Parameters Setting


7. Network Communication Fault

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

SCR Test By Multi-meter


1.A K ()
2.A(-) G(+) ()
G
3.G K (10 ~ 25 )

Tai & Chyun Associates Industries, Inc.

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

T/R Internal HV Cable Breaks

Electrical Troubleshooting
Meter Fault

External Voltage Divider Fault

Improper Meters Calibration


KV, mA, Vp, Ip Meters Fault

Electrical Troubleshooting
Meter Fault
Vp x Ip x Power Factor
= Vs x Is
Vp x Ip x Power Factor

270 x 150 x 0.63


= 25,515 VA

Improper Meters Calibration


KV, mA, Vp, Ip Meters Fault

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

Phase resistance check


Phase insulation resistance check
Supply voltage check
Check setting of motor
overcurrent protection circuit
- refer to motor manual
No load test
Gearbox check

Electrical Troubleshooting
Grounding
Electrical grounding

Electrical Troubleshooting
Grounding

Ensure ground connection

Your First Choice for Electrostatic Precipitator Services

END OF THIS SESSION

You might also like