WPCA AMEREN ESP

SEMINAR
Understanding ESP Controls

By John Knapik
2004, General Electric Company

Efficiency vs. Specific Corona Power

KNOW WHERE YOUR ESP RUNS ON
THE CURVE
99.9

99.0

Collection
Efficiency
(Percent)
80.0

100

200

300

400

500

600

Corona Power Watts/1000 ACFM

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AVC Cabinet, CLR & T/R Set

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Typical SCR-CLR Electrical System

+

SCR Stack
-

L-1

Current Limiting
Reactor (CLR)
Primary Voltage
Meter

Transformer/Rectifier
(T/R) Set

CT

L-2

Primary
Current Meter

A
Secondary
mA Current
Master

Firing
Circuit

Secondary
Voltage
KV
Meter

Microprocessor(s)
Control
Module

Automatic
Voltage Control

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Precipitator
Field
mA

Signal
Resistor

Just Remember, the Primary of a T-R

Set is Rated in Units of RMS, the
Secondary is in Average
400 V AC RMS
120 A AC RMS
45 KV DC Average
750 mA DC Average

Therefore use an RMS Reading Meter to

Calibrate the Primary Meters
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Note! How Do You Tell The

Difference?

Iron Vane
Movement

DArsonval
Average

RMS

The Meter Scale Distance is not the

Same on the RMS Meter.
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Primary Current Meter

+

SCR Stack
-

L-1

Current Limiting
Reactor (CLR)
Primary Voltage
Meter

Transformer/Rectifier
(T/R) Set

CT

L-2

Primary
Current Meter

A
Secondary
mA Current
Master

Firing
Circuit

Secondary
Voltage
KV
Meter

Microprocessor(s)
Control
Module

Automatic
Voltage Control

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Precipitator
Field
mA

Signal
Resistor

Finding the Primary Current Waveform

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Primary Current A Chopped Sine

Wave

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Primary Current Waveform - Positive

and Negative Half-Cycles = SCR 1 and
SCR 2

Secondary Current Meter

+

SCR Stack
-

L-1

Current Limiting
Reactor (CLR)
Primary Voltage
Meter

Transformer/Rectifier
(T/R) Set

CT

L-2

Primary
Current Meter

A
Secondary
mA Current
Master

Firing
Circuit

Secondary
Voltage
KV
Meter

Microprocessor(s)
Control
Module

Automatic
Voltage Control

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Precipitator
Field
mA

Signal
Resistor

11

Finding the mA Signal

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12

Secondary Current Pulsating DC

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13

Typical Primary and Secondary

Current

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14

Secondary Voltage Meter

+

SCR Stack
-

L-1

Current Limiting
Reactor (CLR)
Primary Voltage
Meter

Transformer/Rectifier
(T/R) Set

CT

L-2

Primary
Current Meter

A
Secondary
mA Current
Master

Firing
Circuit

Secondary
Voltage
KV
Meter

Microprocessor(s)
Control
Module

Automatic
Voltage Control

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Precipitator
Field
mA

Signal
Resistor

15

Current Limit - mA & KV

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16

Secondary Voltage Waveforms True

Negative
mA

KVmi
n

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KVpeak

17

Next The Automatic Voltage Control

+

SCR Stack
-

L-1

Current Limiting
Reactor (CLR)
Primary Voltage
Meter

Transformer/Rectifier
(T/R) Set

CT

L-2

Primary
Current Meter

A
Secondary
mA Current
Master

Firing
Circuit

Secondary
Voltage
KV
Meter

Microprocessor(s)
Control
Module

Automatic
Voltage Control

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Precipitator
Field
mA

Signal
Resistor

18

The AVC
is the BRAINS
of the ESP

Older Analog AVC

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20

Microprocesso
r Based
AVC

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21

The AVC has 2 Jobs to Execute

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Control the amount of sparking in the ESP.

If a T/R set is not sparking, then its AVC
should be pushing that T/R set to one of its
pre-set, healthy limits (volts, amps, KV, ma,
or firing angle).
Ill explain what is meant by healthy in a
minute

22

The AVC has 2 Jobs to Execute

But how does the AVC know

whats happening in the
ESP?

Transformer Rectifier Set

e

The mA signal is its eyes!

e
e
e
e
e
e
e
e
e

mA Meter

Current)

Ground
Return
Leg

e
e

Plate
(+)

e
e

e
e

e
e

e
e

e
e

e
e

(Precipitator
Voltage)

e
e
e

KV Meter

KV

(Precipitator mA

e
e
e

e
e

e
e

e
e

e e
e
e
e
e

Electrode
+
+
+

e
e
e

+
+

e e

e
Free Electrons =
Positive & Negative Ions = +
Charged Particles =
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e
e
24

AVC Cabinet, CLR & T/R Set

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25

AVC Spark Response

SPARK
SETBACK

QUENCH

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FAST RAMP

SPARK RATE

26

Good Initial Settings for an AVC

1. Quench = 1 Full Cycle
2. Fast Ramp = 5 or 6 Half Cycles
3. Setback = 15 to 20%
4. Spark Rate = 30SPM

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27

Proper AVC Response to Sparking

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28

Spark Response - Secondary Current

Waveform

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29

Spark Response - Secondary Current

and Voltage Waveforms

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30

Typical Spark Response - mA & KV

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31

Further Control A Search Ramp Rate

New Spark Threshold or T/R Limit
Search Ramp
Spark Threshold

P
O
W
E
R

AUTO PRCS FLWR

Setback

PHASE BACK

Fast Ramp
Quench
(Response to Spark)

INTERRUPT
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Slow Ramp (determined by spark rate)

RAMP

PEDESTAL

T IM E
32

Spit Spark Response (mA)

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33

Spit Spark Response - Secondary

Current and Voltage Waveforms

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34

Examples of AVC s at a Limit

AVC SPARK LIMITED DOING ITS JOB

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36

T/R Current Limited with Sparking

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37

T-R CURRENT LIMITED WITHOUT

SPARKING

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38

T-R VOLTAGE LIMITED WITH

SPARKING

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39

What is meant by Healthy Limits?

Primary or Secondary Limit is not healthy
when accompanied by a Primary Voltage level
< 90 VAC or a Secondary level < 12KV. It
usually indicates a short circuit.
Secondary Voltage Limit is not healthy when
there is very little Secondary Current. It usually
indicates an open circuit.
Neither condition is aiding in particle capture
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40

The T-R Set

+

SCR Stack
-

L-1

Current Limiting
Reactor (CLR)
Primary Voltage
Meter

Transformer/Rectifier
(T/R) Set

CT

L-2

Primary
Current Meter

A
Secondary
mA Current
Master

Firing
Circuit

Secondary
Voltage
KV
Meter

Microprocessor(s)
Control
Module

Automatic
Voltage Control

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Precipitator
Field
mA

Signal
Resistor

41

Transformer Rectifier (T/R) Set

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42

Inside T/R Tank

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43

High Voltage Transformer

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44

Diode Stack

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45

T/R Set Low Voltage

Junction Box

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46

Low Voltage Junction Box

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47

T/R Nameplate

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48

The KV Meter
+

SCR Stack
-

L-1

Current Limiting
Reactor (CLR)
Primary Voltage
Meter

Transformer/Rectifier
(T/R) Set

CT

L-2

Primary
Current Meter

A
Secondary
mA Current
Master

Firing
Circuit

Secondary
Voltage
KV
Meter

Microprocessor(s)
Control
Module

Automatic
Voltage Control

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Precipitator
Field
mA

Signal
Resistor

49

Voltage Divider

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50

SCRS
+

SCR Stack
-

L-1

Current Limiting
Reactor (CLR)
Primary Voltage
Meter

Transformer/Rectifier
(T/R) Set

CT

L-2

Primary
Current Meter

A
Secondary
mA Current
Master

Firing
Circuit

Secondary
Voltage
KV
Meter

Microprocessor(s)
Control
Module

Automatic
Voltage Control

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Precipitator
Field
mA

Signal
Resistor

51

SCR

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52

Typical Sine Wave

SCR
Firing
Angle
(90)

+
-

Power
On

Zero Crossings

Time

Conduction
Angle
(90)

90

180

270

360

8.33 milliseconds
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53

SCR: Low Voltage to T-R Set

Firing Angle 140

Conduction angle 40
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54

SCR: High Power to T-R Set

400

Firing Angle 40
Conduction angle 140
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55

The CLR
+

SCR Stack
-

L-1

Current Limiting
Reactor (CLR)
Primary Voltage
Meter

Transformer/Rectifier
(T/R) Set

CT

L-2

Primary
Current Meter

A
Secondary
mA Current
Master

Firing
Circuit

Secondary
Voltage
KV
Meter

Microprocessor(s)
Control
Module

Automatic
Voltage Control

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Precipitator
Field
mA

Signal
Resistor

56

Current Limiting Reactor (CLR)

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57

Current Limiting Reactor

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58

Current Limiting
Reactor at T-R Set

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59

SCRs are why CLRs are Needed

The diagram would

represent the
waveform with the
SCRs turning on at 90.
If this waveform were
applied to the T/R set,
very inefficient
operation would occur.
Output power from the
T/R set would be
greatly reduced.

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90

90

60

Electrical Basics: CLR

To increase the efficiency of the T/R set, a device called a
CLR (current limiting reactor) is used. A CLR is an inductor.
Recall that the property of an inductor is to oppose a change
in current. Because of this property, the shape of the current
waveform is changed and it starts looking more like a sine
wave.

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61

CLR Function

Limit short circuit current

Shape T/R secondary wave to be more
sinusoidal
Provide proper form factor
Protect SCRs and T/R diodes from steep
current rise
Increase precipitator voltage and current
Not to be confused with air core reactor

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62

CLR Waveform Changes with

Impedance

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63

Proper CLR Sizes for Common T/R

Sets
All T/R primaries are rated at 400V

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PRI Current
(Amps)

Sec. Current
(mA)

40
80
120
160
200
240

250
500
750
1000
1250
1500

Minimum
(mH)
13.0
6.6
4.4
3.3
2.6
2.2

64

Basic Troubleshooting

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TR Nameplate Values
(For this exercise)
Primary Current

160 Amps

Primary Voltage

480 Volts

Secondary Current

1200 mA

Secondary Voltage

45 kV

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66

160

480

First Indication
1200

45

Second Indication

Short
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67

Close Clearance
160

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480

1200

45

68

Conductive Dust, Outlet

Field
160

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480

1200

45

69

Bad KV Return
160

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480

1200

45

70

Open
160

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480

1200

45

71

Normal Running
Condition
160

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480

1200

45

72

SCRs Not Firing

160

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480

1200

45

73

Questions?

Thank You.