First Pack of Solution For ESPs Improvement

First pack of solutions for ESP improvement: corrosion, isolation,
isolation electrical
Title
isolators,, emitting electrodes and coating for electrodes.
Date 27/06/2014
Project ESP improvement
Authors Virgilio Garca, Francisco Voces
Client ---
Version V0
2014 ArcelorMittal All rights reserved for all countries

Cannot be disclosed, used, or reproduced without prior written specific authorization of ArcelorMittal
CONFIDENTIAL Privileged Information - ArcelorMittal's proprietary information
Global R&D Asturias
Content
1 Introduction ................................................................................................
................................ ............................................... 5
1.1 Summary of contents................................................................................................
................................ ....................................... 6
2 Corrosion in ESP ................................................................................................

................................ ...................................... 7
2.1 Mechanism of corrosion................................................................................................
corrosion ................................... 7
2.2 Types of Corrosion ................................................................................................
................................ .......................................... 7
2.3 Critical
al Areas of Corrosion Attack in Precipitators ............................................................
................................ 9
2.3.1 Outer Shell Walls ................................................................................................
...................................... 9
2.3.2 Roof ................................................................................................
................................ ....................................................... 10
2.3.3 Collector Plate Surfaces ................................................................
......................................................... 10
2.3.4 High Voltage System ................................................................
.............................................................. 11
2.3.5 Hopper Areas ................................................................................................
................................ ......................................... 12
2.3.6 Access Doors ................................................................................................
................................ ......................................... 12
2.3.7 Discharge Electrode ................................................................
............................................................... 13
3 Thermal insulation ................................................................................................

................................ .................................. 14
3.1 Casing ................................................................................................
................................ ........................................................... 14
3.1.1 Rockwool................................................................................................
................................ ................................................ 14
3.1.2 Seal gaskets ................................................................................................
................................ ........................................... 16
3.1.3 Access door................................
................................................................................................
............................................ 18
3.2 Leakage detection ................................................................................................
................................ ......................................... 20
3.2.1 Non destructive testing methods................................................................
methods ............................................. 20
3.2.1 Thermographic cameras ................................................................
......................................................... 22
3.2.2 Smoke Generator ................................................................................................
................................... 23
4 Electrical Insulators ................................................................................................

................................ ................................ 24
4.1 Material
rial have been used for ESP insulators ................................................................
.................................. 24
4.2 Material requirement for different insulators ................................................................
................................... 25
4.3 ESP insulator failures ................................................................................................
.................................... 26
4.4 Method
thod to avoid thermal breakdown and delay insulation aging. ...................................
................................ 28
4.5 Size and shape design ................................................................................................
.................................. 30
4.6 General maintenance of insulators ................................................................
................................................ 31
4.7 Self-Cleaning
Cleaning insulators ................................................................................................
................................. 32
4.7.1 Purge air system ................................................................................................
.................................... 33
ArcelorMittal 2014 ArcelorMittal All rights reserved for all countries
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4.8 Evaluation of porcelain faults ................................................................

........................................................ 35
4.9 Repairs ................................................................................................
................................ ......................................................... 36
4.9.1 Repair of porcelain
elain with the broken piece available ................................................
................................ 36
4.9.2 Filling of chips and voids where the piece is missing ..............................................
................................ 37
4.10 Glazing ................................................................................................
................................ ...................................................... 37
4.10.1 Types of glazing ................................................................................................
................................ ..................................... 38
4.10.2 Semiconducting glaze ............................................................................................
............................ 38
4.10.3 Hydrophobic glaze ................................................................................................
................................ ................................. 40
5 Type of electrodes ................................................................................................

................................ .................................. 42
5.1 Discharge electrode ................................................................................................
................................ ...................................... 42
5.2 Collecting electrodes ................................................................................................
................................ ..................................... 43
6 Anticorrosion coating of discharge electrode .....................................................

................................ 45
6.1 Study about non-metallic
metallic coatings................................................................
................................................. 45
6.2 Metallic coatings ................................................................................................
................................ ........................................... 48
6.3 Composite discharge electrode ................................................................
..................................................... 50
7 Conclusions ................................................................................................
................................ ............................................ 56
8 Bibliographic references ................................................................

....................................................... 57

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1 Introduction
There has, in recent years, been an increasing awareness and world-wide

world wide recognition of the
problems associated with atmospheric pollution; consequently, most industrialized nations have
enacted legislation to limit uncontrolled emissions from all sources.
One of the most suitable forms of arrestment device for meeting these levels of emission,
particularly for process plants producing large gas flow rates, is the electrostatic precipitator.
The features of the electrostatic precipitation process,

process, which produces an ideal vehicle for the
removal of particulates, are as follows.
Versatility effective
ective performance on a wide range of industrial processes. Can be designed
to meet any required effifficiency and sized for any gas flow rate.
Can collect particles over the complete size range spectrum. Dust is usually recovered in its
original state. But plants can be designed to operate as a wet phase device if required,
particularly for gases close to, or at, dew point temperature.
Low pressure loss, typically
pically less that 5 mbar.
Acceptable electrical power consumption for required efficiency level.
Robust and reliable construction life expectancy >20 years.
The basic theory of operation is that the raw gas dust particles are passed through a corona or
charging field where they receive an electric charge, usually negative in the case of industrial
precipitators, and then as charged particles are deflected by the electric field producing the
charging regime. The charged
harged particles then move across the gas stream from the negative
electrode to be deposited on the positive electrode, which for convenience is normally earthed or
grounded. From the collectors, the particles are removed into receiving hoppers or troughs, either
by mechanical shock impulse rapping.
Commercially, electrostatic precipitators have been used for almost a century for the collection of
dust, fume and mist particles from all types of processes. The initial applications from mainly
chemical/metallurgical
lurgical based applications were both for reducing air pollution and for the recovery
of valuable byproducts, for example the cleaning of combustible gases, or material losses from
metal smelting processes. The ability to size precipitators for a specific efficiency was ideal in this
respect and economics dictated mid-90%
mid 90% efficiencies for this recovery type of application, since the
collected material normally had a positive value.
More recently, the major application has been to control air pollution to meet
m specific legislative
emissions and, consequently, design efficiencies can now approach, and sometimes exceed, 99.9%.

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1.1 Summary of contents
These guidelines are intended for use by workers with a professional interest in the practical
application of electrostatic. It is intended to be complete insofar as the information needed for a
working knowledge of the subject is concerned. Complex mathematical derivations and in-depthin
theoretical studies have been intentionally summarized or omitted wherever possible,
pos in order to
save the reader time, and to enhance the usefulness of this manual. However, adequate references
are included for those wishing to delve
de deeper.
Many key issues are going to be faced below:

below
Main points of corrosion
ESP thermal insulation
ESP electrical insulators
Discharge electrodes
Collecting plates

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2 Corrosion in ESP
For many years, the electrostatic precipitator has proved an effective device for the removal of
particulate matter from flue gas streams in the utility, cement, and iron and steel industries. The
day to day maintenance of high efficiency collection is known to be related to many factors of
equipment design and process variables. Of equal importance from an economic and performance
standpoint is howw the gas and dust characteristics affect the useful life of the metallic parts of the
precipitator. The purpose of this part is to define areas of corrosion attack in the dry type
precipitator. Methods based on field observations for limiting and controlling specific areas of
corrosion are discussed.
2.1 Mechanism
anism of corrosion
As noted already, corrosion in electrostatic precipitators is caused by sulfuric acid (acid dew point
corrosion) formed from the sulfur trioxide in the flue gases. This occurs via [1]:
[1]
SO3 + H2O -> H2S04
Thus S03 and H2O concentration are vital factors in determining dewpoint and therefore corrosion.
This sulfuric acid in the flue gases can condense if the temperature falls below the dewpoint for the
acid. The Verhoff-Banchero equation can be used to determine the acid dewpoint once the SO3 and
H20 compositions are known [1]
where
here T is degrees Kelvin and pressures are in atmospheres. Alternatively, the SO3 concentration
could be estimated if acid dewpoint and water content were known. Dewpoint increases as PSO3
and PH2O increases, which means that in gases with more SO3 acid can deposit at higher
temperatures [1]. Acid dewpoint
nt temperature is usually around 130 C.
2.2 Types of Corrosion
There are several different and well recognized types of corrosion that can occur, depending upon
various specific conditions. Broadly considered, corrosion is a natural process of reverting refined
metals to their original orese.g.,
e.g., oxides. It is an electrochemical process involving the migration
of ionic species in some type of electrolyte solution. Loss of metal, i.e., corrosion, takes place
where the current leaves the metal and enters the solution. This area is called the anode; the
cathode is the protected region. The anode and cathode may be 2 different metals or different
areas of the same metal.

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Briefly, the various types of corrosion may be summarized as follows [2]:

Uniform AttackLarge Large metal surfaces in contact with acids, caustics or other solution. High
temperature oxidation frequently takes this form too.
PittingSmallSmall areas under intense attack involving local breakdown of protective coatings
or oxide layers. Such areas often act as starting points for stress corrosion.
Concentration CellTypically
Typically occurs
occu in cracks.
IntergranularSelective
Selective attack along grain boundaries; may be associated with cooling
from welding temperatures.
Stress CorrosionHigh High tensile stress in a corrosive atmosphere
atmosphere leading to premature
metal failure, breakage.
FatigueCyclic loadss plus corrosion leading to metal failure and breakage below the limit
for noncorrosive conditions.
Selective AttackOne One element of an alloy involved.
High TemperatureParticularly
Particularly where nonprotective oxide layers may be present due to
spalling; sulfidation,
n, carburization, or decarburization factors.
Impingement AttackScouring Scouring by flow media exposing bare metal, eroding metal, breaking
through scale layers.
FrettingAt At tight metal fits usually subject to high frequency vibrations, possibly galvanic
and/or concentration
oncentration cell actions.
Dissimilar MetalsSetting Setting up galvanic action due to potential differences; severity
depending upon the metals position in the galvanic series.
Typical examples of various corrosion types in electrostatic precipitators may be illustrated briefly
as follows [2]:
Uniform AttackCollecting
Collecting plate surfaces, hoppers, shell, and roof.
PittingNearNear air inleakage areas, discharge electrodes, and rapper rods.
Concentration CellsJointsJoints and corners, and air inleakage sites.
IntergranularAt At welds, and collecting plate supports.
Stress CorrosionDischarge
Discharge electrodes at tight bends, especially certain stainless steels.
FatigueDischarge
Discharge electrodes at terminations, rapper anvil weld areas, collecting plate
hangarar areas, and high voltage strap connections.
Selective AttackDischarge
Discharge electrodes and copper cladding on discharge wires with NH3
conditioning.
High TemperatureNot Not too common below 700P, more usually associated in boilers, and
in internal steel and rooff plate gunite spalling can occur.
ImpingementErosionErosion due to abrasive dusts.
FrettingDischarge
Discharge electrode terminations and fittings.
Dissimilar MetalsDischarge
Discharge electrode terminations and fittings, copper grounding strap
connections, and copper high voltage strip connections to HT electrode frames.

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2.3 Critical Areas of Corrosion Attack in Precipitators
A large number of physical components of the precipitator become exposed to the potential attack
of corrosive atmospheres. The following discussion identifies critical zones of the precipitator that
are the most vulnerable to metal damagetypically,
damage typically, (1) outer shell walls, (2) roof, (3) collector
plate surfaces, (4) high voltage system, (5) hoppers, (6) access doors, (7) expansion joints, and (8)
test ports,, (9) discharge electrodes [2].
2.3.1 Outer Shell Walls

The shell walls of the precipitator, generally 3 to 6 mm.. thick, provide pockets of potential
corrosion at support steel and baffles located between the outer collector plates and walls. This
wall surface is the interface between the inner gas conditions and the outside air environment and
thus is most susceptible to condensation problems if proper heat containment is not applied.
Figure 1. Corrosion in outer Shell near to TR.

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2.3.2 Roof
Of special concern for possible corrosion attack is the roof header plate that provides the gas seal
at the top of the precipitator as well as the support for many insulator and rapper
rap devices. Several
factors make this plate critical:
1. The upper support structure provides numerous pockets and ledges for material deposits.
2. During normal operation and during shutdowns, air intake (possibly moist) is often provided
in the upper compartments ents or penthouse to sweep deposits from the surfaces of the
insulators. (Problems that could be solved by some further recommendations)
3. The internal height of the precipitator produces a slight chimney effect during process
proc start-
ups which allows the warmer,
warmer, moist gas to rise to the cold roof plate. Repeated "operations
aggravate the corrosion potential at this location.
4. Integrity of the roof deck insulation is difficult to maintain.
Figure 2. Roof corrosion
2.3.3 Collector Plate Surfaces
The large area of thin metal causes concern for the magnitude of possible corrosion of the
collection plate surfaces. There are critical corrosion zones for the collector plates that are
dependent upon the physical location within the precipitator as well as the specific location on the
plate. Briefly:
1. The plates adjacent to the outer shell walls are subject to the maximum temperature
variations and possible dewpoint conditions.
2. The lower portions of the collector plates, especially
especiall toward the gas outlet of the
precipitator, become sensitive to temperature variations.

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3. The top portions of the collector plates can be affected by the flow of air through support
insulators.
4. The type of fabrication used to reinforce or stiffen the collector
tor plate can provide crevices
for corrosive action.
5. Misalignment or bowing of the collector plate can cause localized metal erosion from
excessive electrical breakdowns between the electrode systems. Sharp edges on the
collector surface can cause localized
localize electrical activity which can produce metal erosion.
Figure 3. Collector plate corrosion
2.3.4 High Voltage System
Corrosion attack in the high voltage system can take several forms:
1. Stress corrosion of the high voltage electrodes can occur at excessive bends or can be
aggravated by stresses formed during fabrication.
2. The use of dissimilar metals at the terminations of wire electrodes can set up pitting as well
as excessive galvanic activity.
3. Metal fatigue provides
ovides a potential area of electrode failure because of excessive vibration
or whipping of the wire often related to the design of the equipment.
4. Metal erosion can occur from electrical activity in localized areas.

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2.3.5 Hopper Areas
The surfaces of hopper walls will usually be exposed to the lowest gas temperatures in the
precipitator. Modern practice is to provide sufficient heat insulation as well as external heaters to
help maintain the inside wall temperaturas above the dew point levels of the gas. Smooth surfaces
(including rounded corners) and the slope of the Hopper walls generally provide minimal pockets
for localized corrosion attack. There are several points of interest:
1. Potential air inleakage through the valving at the discharge
discharge of the hoppers can cause
difficulties.
2. It is extremely difficult to maintain the integrity of the heat insulation system at the apex of
the hopper, especially if the initial designs
design of the hopper appointments are less than
optimum. If small sections of insulation are removed for maintenance purposes,
subsequent wall cooling can provide a potential for corrosion.
3. Exposure of the walls to any wind chill factor can cause material encrustations to form on
the interior surfaces. This condition can initiate corrosion attack at the interface of the
build-up
up and wall surface of the hopper.
A possible solution in this area is to use Duplex Steel 2205 or SuperDuplex 2507 with smaller
thickness. It will solve this issue.
Standard Duplex
Supply 0.78 /Kg 3.10 /Kg
Weld 2.90 /Kg 3.2 /Kg
3.20
Thickness 6 mm 3.5 or 4 mm
Total price(*mm/Kg) 22.08 22.05 or 25.20
Table 1. Features of steel
2.3.6 Access Doors

Access doors either on hoppers or for entry to the precipitator proper are potential corrosion sites.
Specifically:
1. Seals at the door plate edges can deteriorate with time and allow cold air inleakage to
occur.
2. The design of the door frame usually allows a build-up up of material to occur and react with
the cooler surfaces where moisture-dilute
moisture dilute acid condensation may take place.
3. It is difficult to provide and maintain a proper insulation seal at access doors, especially at
the hopper locations.

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Figure 4. Access door corrosion, inside view
2.3.7 Discharge Electrode
The steel frames used to support groups of the ionizing electrodes are insulated from ground
potential by porcelain,, alumina or silica insulators. This corrosion may be attributed to-localized
to
cooling due to poor
or insulation or air in-leakage.
in leakage. Heated purge air (kept to a minimum) should be
used to keep the support insulators clean and free of moisture. Corrosion fatigue can occur at
discharge electrodes
des at terminations and high-voltage
high strap connections.
Figure 5.. Dust accumulation on the discharge electrode surface

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3 Thermal insulation
3.1 Casing
The casing can weigh several hundred tones and is an important part of the overall design. Not only
must it be completely gas tight, but must also withstand all the various loads imposed on it without
distortion, in order to maintain electrode collector alignment. The loads would include wind, snow
sno
and possibly seismic conditions, in addition to the dead load of the internals, plus dust deposits on
the internals and hoppers.
Casings are generally designed to international standards utilizing the 'allowable stress' in the
material, for load, gas pressure
essure and temperature, etc.; alternatively, some casing designs are now
based on 'deflection under load'. As any precipitator structure must be rigid enough to maintain
electrode alignment and to contain the gas under all conditions, the design based on 'deflection',
rather than 'allowable stress', can result in an optimum weight/cost
weight/cost arrangement.
To ensure that the casing is gas tight, any access doors and cut-outs cut outs used for rapping
drives/insulators, etc., or instrumentation, must be carefully considered and designed such that
they can be sealed effectively. Any air ingress into an operating precipitator will not only result in
electrical disturbances but invariably causes local corrosion from the gas being cooled below dew-
point. Any door used for man access,ac in addition to having effective sealing, should also be
electrically key interlocked for safety reasons, as the operating voltage on any precipitator is lethal.
On the majority of dry precipitators the casing is thermally insulated to reduce corrosion
corrosio and give a
long life. The thermal insulation, or, at least its fixing to the steel work, needs to avoid all thermal
bridges; otherwise corrosion can occur on the inside of the casing, which could ultimately affect its
mechanical integrity and possibly, ini the short-term, electrode alignment [3].
For the correct continuous improvement of the sealing is recommended to install some O2
measurements before and after the ESP to verify the tightness.
tightness Below, there is a price comparison
between 2 ways of measuring O2.
Lambda sensor Zirconium oxygen analyzer

50 to 200 2000-5000
5000
Table 2. Price comparison between oxygen analyzer
3.1.1 Rockwool
In order to prevent ESP,, as much as we can, from the acid dew point corrosion, shell of ESP is
covered with a thermal insulation. The most widespread thermal insulator in ESPs world is
Rockwool. It is so used due to its good properties.
properties Several main features of rockwool are:

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Low thermal conductivity

onductivity
Highly water repellant
High temperature resistant
High acoustic resistant
Fire resistant
There are a great deal of types of Rockwool and a lot of manufacturers as well,
well but for this
document it has been chosen as a representative
represe manufacturer: Rockwool.
Depends on the manufacturer, there are a wide variety of prices. The prize of a rockwool panel also
varies with its thickness. Below, it is showed the prices of some different panels:
panels
Rockwool panels prices
= 70 Kg/m3
Thickness*Width*Length (mm) /m2)
Price (/m
100*1000*2400 19.25
150*1000*2400 29.25
200*1000*2400 39.3
39.32
Table 3. Price of rockwool low density panel
= 100 Kg/m3
Price (/m
100*1000*2400 23.37
150*1000*2400 35.05
200*1000*2400 46.75
Table 4. Price of rockwool medium density panel
= 125 Kg/m3
Price (/m
100*1000*2400 28.89
150*1000*2400 43.33
200*1000*2400 57.78
Table 5. Price of rockwool high density panel

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3.1.2 Seal gaskets

In order to prevent ESP from flue gas leakage in the access doors, it is necessary to use a properly
seal. There are a many different kinds of seals, but for ESPs is common to use a seal made of
expanded PTFE (ePTFE).. The most important features of seals are:
Trend Material T (C) PH Pression

Gore serie 600 PTFE exp. -268 a 315 0 14 6 bar
Aidmerptfe 7612R PTFE exp. -288 a 316 0 14 30 Mpa

Manuf Rubber
PTFE exp. -288 a 316 0 14 21 Mpa
MRS seal
YMT-PTFE Joint
PTFE exp. -288 a 316 0 14 16 bar
Seal
Seal sales- PTFE
PTFE exp. -288 a 316 0 14 20.7 Mpa
Joint Sealant
Vdipesh-PTFE
PTFE exp. -260 a 260 0 14 20 Mpa
Expanded
Thermosealinc--
PTFE exp. -321 a 260 0 14 13 Mpa
Sealex
Table 6. Features of seals
Below, there is a list of some prices of seals from SEAL SALES-PTFE:

SALES
Size Prize ($)

1/8 x 100 61.16
3/8 x 25 56.84
1/2 x 15 113.56
5/8 x 15 106.40
5/8 x 30 212.80
3/4 x 15 138.70
3/4 x 30 277.40
Table 7. Prices of several sizes of seals

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Figure 6. Seal installation
Figure 7. Corroded seal

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3.1.3 Access door

Corrosion is majorly caused due to in-leakage
in leakage of cold air into the precipitator, thus chilling the flue
gases to below the acid dew point. This causes the condensation of moisture and gases on the
casings, resulting in the damage of inner walls and also collecting plates and discharge electrodes.
The maintenance costs or replacement costs are huge. Double access doors, proper sealing and
insulation are inexpensive ways of preventing most cases of corrosion [4].
Access doors are doors to provide access to different functional areas of an ESP. They are sturdy
and thermally well insulated. One might think that access doors are just a simple door for accessing
acc
into the ESP chambers, but in fact, access doors are very important to the ESPs conditions. Access
doors can be single access door or double access door. Single access doors are not as protective as
double access doors as it may lead to serious corrosion
cor due to in-leakage
leakage of cold air from poor
gasket or improper sealant. Double access doors are widely used by quality conscious companies.
The outer door frame is seal welded to ESP casing, and insulation cladding is placed around the
outer door frame to provide proper thermal insulation [4].
Double access door have double protection and can prevent the dust from flowing out and cold air
from leaking in. The access doors are high temperature resistant. They have double sealing, thus
preventing in leakage/heat exchange and thereby prevention of corrosion. This reduces the ESPs
maintenance costs [4].
Figure 8. Double door

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Figure 9. Insulation between indoor and outdoor in double doors
Typical Installation Instructions of a double door
1) Cut out or move secondary casing stiffeners which are in the way. Cut the opening in the
casing wall and install the temporary support bars.
2) Invert frame if opposite hinging is required. Clamp the frame plate to the casing wall and
stitch weld the perimeter slots to casing. Then seal weld inner face of frame plate to edge
of opening in casing.
3) Adjust sag rod and install hinge stiffeners. If there is no outer door then views 4 & 5 are not
required.
4) Telescope outer door sleeve onto the inner frame until perimeter flage is flush with
cladding. Stitch Weld sleeve to inner frame.
5) Finish insulation and screw lagging around outer frame.

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Figure 10.
10 Steps for the installation of a double door
3.2 Leakage detection
3.2.1 Non destructive testing methods

NDT stands for non-destructive
destructive testing. In other words it is a way of testing without destroying.
destroying
This means that the component- the casting, weld or forging, can continue to be used and that the
non destructive testing method has done no harm [5].
In today's world where new materials are being developed, older materials and bonding methods
are being subjected to higher pressures and loads, NDT ensures that materials can continue to
operate to their highest capacity with the assurance that they will not fail within predetermined
time limits.
NDT can be used to ensure the quality right from raw material stage through fabrication and
processing to pre-service and in-service
service inspection.
inspection
No single NDT method will work for all flaw detection or measurement applications. Each of the
methods has advantages and disadvantages,
disadva below it is showed a summary
summar of the scientific
principles [5]:

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Penetrant testing
Magnetic particle testing
Ultrasonic testing
Eddy current testing
Penetrant solution is applied to the surface of a precleaned component. The liquid is pulled into
surface-breaking
breaking defects by capillary action. Excess penetrant material is carefully cleaned from the
surface. A developer is applied to pull the trapped penetrant back to the surface where it is spread
out and forms ann indication. The indication is much easier to see than the actual defect.
Used to locate cracks, porosity, and other defects that break the surface of a material and have
enough volume to trap and hold the penetrant material. Liquid penetrant testing is usedu to inspect
large areas very efficiently and will work on most nonporous materials.
A magnetic field is established in a component made from ferromagnetic material. The magnetic
lines of force travel through the material, and exit and reenter the material at the poles. Defects
such as crack or voids cannot support as much flux, and force some of the flux outside of the part.
Magnetic particles distributed over the component will be attracted to areas of flux leakage and
produce a visible indication.
Used to inspect ferromagnetic materials (those that can be magnetized) for defects that result in a
transition in the magnetic permeability of a material. Magnetic particle inspection can detect
surface and near surface defects.
High frequency sound waves are sent into a material by use of a transducer. The sound waves
travel through the material and are received by the same transducer or a second transducer. The
amount of energy transmitted or received and the time the energy is is received are analyzed to
determine the presence of flaws. Changes in material thickness, and changes in material properties
can also be measured.
Used to locate surface and subsurface defects in many materials including metals, plastics, and
wood. Ultrasonic
onic inspection is also used to measure the thickness of materials and otherwise
characterize properties of material based on sound velocity and attenuation measurements.
NOTE: According to many experts, high

igh frequency sound waves are really useful when the
t possible
leakage zone is almost located
Figure 11. High frequency sound waves method

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Alternating electrical current is passed through a coil producing a magnetic field. When the coil is
placed near a conductive material, the changing magnetic field induces current flow in the
material. These currents travel in closed loops and are called eddy currents. Eddy currents produce
their own magnetic field that can be measured and used to find flaws and characterize
conductivity,
ductivity, permeability, and dimensional features.
Used to detect surface and near-surface
surface flaws in conductive materials, such as the metals. Eddy
current inspection is also used to sort materials based on electrical conductivity and magnetic
permeability, and measures the thickness of thin sheets of metal and nonconductive coatings such
as paint.
Figure 12. Eddy currents meth
3.2.1 Thermographic cameras

Apart from NDT methods, there are more ways of controlling and detecting leakages on the surface
of the shell. One of them might be by monitoring the shell of the ESP with thermographic cameras.
It would be a fine method for controlling cold points and supervising its progression. Below there
are some examples of high quality portable and permanent cameras.

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Trend Fluke Fluke Testo Testo Testo Nec/Avio

Ti400 Ti50FT 876 885 890 VarioCam HD
Code
Price 8000 $ 16800 $ 3200 6300 12000 -
-20 a 1200 - a 600
-20 -20 a 350 -20 a 350 -20
20 a 350 -40 a 1200
T (C)
Precision 2C o 2%
2C o 2% - - - 1.5%
Vision 24 x 17 42 x 32 - 30 42 67 x 50
Pixels 320 x 240 320 x240 320 x 240 640 x 480 1280 x 960 1024 x 768
Protection IP54 IP54 IP54 IP54 IP54 IP54

Table 8. Features of portable cameras
Trend Fluke Fluke Testo Testo Testo Nec/Avio

ThermoView A15sc ARC-8-FOV- A6700sc Avio TS9260 FTI-E-800
Code Pi20LTRC 500-Rate
Price - - - - - -
T (C) -40 a 500 - a 550

-40 0 a 500 -20 a 350 -40
40 a 500 -20 a 120
Precision 2C o 2% 0.5C - 2C o 2% - 1.5%
Vision 24 x 17 48, 39 60, 46 48, 39 21.7, 16.4 32 x 16
Pixels 320 x 240 320 x 256 384 x 288 640 x 480 640 x 480 320 x 240
Protection IP67 IP40 IP65 IP65 IP54 IP65

Table 9. Features of permanent cameras
3.2.2 Smoke Generator

Another way to identify flue gas leakages on the surface of the shell
s ell might be by using a smoke
generator. Due to the pression differences between the inside of the ESP and the atmosphere
pression, it is produced a suction from outside to inside of ESP. So, if we used a fumes generator
close to the shell surface and fumes led to inside, a leakage would have been found.

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4 Electrical
ectrical Insulators
ESP insulators are different from other electrical insulators. Not only should they have big creep
distance and dust-free
free shape, but also should their materials have good mechanical, electrical and
thermal properties so that they can normally working in the high temperature, high humidity and
dusty gas environment.
High voltage electric field combining with high temperature may lead to ESP insulator failure.
Particulates having a relatively lower breakdown voltage strength stick on the
the insulator surface can
induce corona discharge and local temperature rise thereby speed insulator aging. Select insulator
with higher Te (the temperature when the resistivity lowers to 1M*cm)
1M *cm) and optimize design to
even the field around insulator can effectively
effectively protect insulator from heat breakdown and aging.
Insulator is a key component of ESP for high voltage operation. How to ensure its insulation
capability on high voltage, high temperature and pollution working conditions is worth studying.
Arbitrary
ry electric porcelain may not be competent at this job. Select suitable insulator material is
important.
Figure 13. Electrical insulator
4.1 Material
aterial have been used for ESP insulators
Materials for ESP insulators have been to be common electrical porcelain, high strength porcelain,
quartz, high alumina porcelain and high polymer materials. At the initial stage, common standard
electrical porcelain insulators were used directly as ESP insulators. Their working life has been short
sho
because of the grimmer environment, so fusion quartz and high strength porcelain materials are
used instead of standard electrical porcelain in later time. Fusion quartz has very good insulation
capability but has weaknesses of fragile and quick reducingg of resistivity as temperature rises,
hence seldom used today. High strength porcelain, such as alkali aluminum silicate and high
strength bauxite porcelain, already instead of standard porcelain are used as the material of ESP
insulators [6].
High polymer material has the advantageous of low price and non-fragile,
non fragile, so it has been widely
used in common sense [6].
Special made high strength electric porcelain (such as 50% alumina porcelain) and high

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alumina porcelain (such as 85% alumina porcelain or 95% alumina porcelain) as a whole series, can
satisfying all the usage of ESP under different and grim conditions with long working life of not less
than 30 years, the same life as ESP [6].
4.2 Material
aterial requirement for different insulators
Firstly, ESP insulator materials should have good electrical insulation capability under high voltage
and the working temperature. Next are temperature endurance and high strength. Generally
speaking, for ESP working below 170 C, C, standard electrical porcelain and 50% alumina can be
used. For that of below 250 C,C, 50% c is suitable. For ESP working above 250 C,
then 85% or 95%
should be considered [6].
Table 10.
10 Characteristics of different porcelains [6]

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Table 11 lists the recommended material of different insulators commonly used in ESP.
Table 11. Recomended porcelain for each insulator [6]
4.3 ESP insulator failures
At the beginning, people regarded the ceramics as brittle material and mechanical failure is
dominative. So, thicker walls, bigger side and higher compressive strength were pursued and
macromolecular rapping rods replaced ceramic rods. But failure still occurred. In some cases,
insulator looked maintaining well appearance but no high voltage was attained. The conclusion is
that the thermal
ermal breakdown and insulation aging induced the insulator failure [7].
[7]
Thermal breakdown
Solid dielectric medium normally conducts

conduct to molecular structure destruction, insulation capability
disappears accompanying with continuous or discontinuous current peak. There are electronic,
thermal and mechanical breakdown, which occur simultaneously or alternatively, hard to identify
clearly [7].

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The reasons for thermal breakdown

breakdow are [7]:
1) It is the external field destroys energy balance that causes intrinsic breakdown and
avalanche breakdown.
2) It is the tunnel effect that electrons passing through valence band to conduction band
causes Zener breakdown.
wn.
Figure 14. Support insulator crack
High temperature working condition will cause insulator breakdown due to combined action from
electrical and thermal. For example, one kind of electrical ceramic has a good insulation capability
in normal temperature which means the energy we applying on ions by electric field is not
enough to support ions pass through valence band to conduction band. While in an ESP, the heat
from flue gas will apply extra energy to the ions in crystal lattice. The more energy ions have from
outside, the higher probability
ty to pass through valence band to conduction band; the more ions in
the material with a wide forbidden band (the range between valence band and conduction band).
The foundation of thermal breakdown is the heat balance between We+Wg=Qf (the energy applied applie
to solid crystal lattice by electric field and temperature field, which raises the lattice temperature)
and the heat dissipated from whole crystal lattice system.
Not only field voltage determines insulators thermal breakdown, but also ambient temperature
tempera
and material properties, such as high temperature durability (lower Te, lower break down) heat
conductivity (lower conductivity, lower breakdown strength), etc. Insulator thickness and high
voltage duration also play their roles.

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Insulation aging
Gas breakdown induces local corona discharge, mass quantity of positive and negative ions
impacting solid surface, causes aging of insulator [7].
Figure 15. Example of insulator aging
For ceramic material, if small hole exits inside gas electric discharge will cause high temperature up
to 170 C, within an area of 5*10-11 cm2, minor crack will appear once thermal expansion stress
exceed
ceed its allowable tensile stress. The minor crack
crack will continuous to expand under the electric,
thermal and rapping forces. Insulation
sulation failed at last. So we can say that local discharging is the
prime culprit for insulator aging.
4.4 Method to avoid thermal breakdown and delay insulation aging.

aging
Select material with excellent electrical characteristic under high temperature
In some countries, normal high voltage electrical ceramics is no longer used in ESP for a long time.
Instead of it, 50% aluminum
um is for low temperature (less than 50%), 85% aluminum is used for 150-
240 C. For temperature higher than 250 C, 95% aluminum will be used [7].
Prevent local discharging
To avoid local discharging, first of all, internal bubbles, pores and cracks must be eliminated as
much as possible. Secondly, reasonable structure design helps uniform electric field distribution.

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Nowadays,ys, there are two methods to make insulator mould: vacuum wet and uniform static
pressure. The first one gives the mould high water content, and also lead to laminate cracking or
porous structure, some of them will be broken under high temperature, all these
the will cause internal
bubbles and cracks. No clay is used in uniform static pressure process, gives the mould very low
water content. Under 100 MPa pressure compressing, mould internal structure is uniform and
highly compact, rarely has bubble and crack inside
i [7].
Making a uniform field distribution near the insulator surface can reduce the possibility of local
corona discharge.
Basically speaking ESP insulators is a non-uniform

non uniform field insulation structure, such as rotating shaft,
rapping bar, supporting bar and pull rod, etc. Wall bushing belongs to extra-non-uniform
extra field
insulation structure. Support bushing located at the middle
middl of both above.
The following provisions can reduce the non-uniform

non degree of insulators [7].
[7]
For wall bushing, keep the ratio of outside and inside diameter D/d about 2.7. As we know
in a cylinder capacitor,
r, the strongest field strength is at the r1, of the inside surface.
Shape the hot end (insert into ESP) of wall bushing to be an umbrella.
Conductive layer are applied on the surfaces of inside hole and outside roots at the ends
close to the flange. Insert a spring leaf between high voltage rod and inner hole so as to
make the air gap to be a short circuit. This not only makes electric force line passes through
just one medium, but also reduces
reduce field concentration.
All corners of the metal parts are around to eliminate local
local high voltage concentration.
A hyperbolic protection tube added at the bottom end of support upport bushing
bushin will endure the
biggest field. It not only prevented the bushing from flashover but also, also even the field
strength and keep dust free.
Increase the insulators leakage length and reduce the insulators diameter. Generally do
not use umbrella, if have to use, use downward shape umbrella for vertical insulator and
symmetrical wave shape umbrella for horizontal insulator. For 95% alumina ceramic wall
bushing, 50 mm of diameter is enough for general high voltage use. Small diameter is
beneficial to heat dissipation.
Cleaning insulator periodically is necessary to prevent insulator aging. Clean once a month
normally, but for heavy polluted insulator, every 15 days and heat air purging system is
recommended.
Using uniform static pressure shaping high alumina insulator is a good choice. Occasionally
flashover will not lead to heat breakdown, on the contrary, due to the electro-dynamic
electro
effect, contamination attached
attached to the insulator surface can be cleaned away (self-cleaning).
(self

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4.5 Size and shape design
For insulators working outside of ESP shell, their shape and electrical creep distance can be
designed similarly as the common electric insulators. For insulators
insulators working inside ESP shell,
directly naked in the dusty gas, its electrical creep distance should be considered according to dust
resistivity and its shape decided by dust angle of repose and stickiness.
High voltage ESP insulators can be divided into two classes. Break down class A include wall
bushing and inner heating condensation-proof
condensation proof insulators. The other types of insulators belong to
non break down class B.
The following factors should be considered in ESP insulators design from the electric and
mechanical point of view [7].
Check Dangerous Cross Section

Mechanical Strength----Check
Insulator size and detailed dimensions of course should be considered for mechanical strength.
Checking dangerous cross section strength is necessary with a safe factor of not less than 1.5.
Material Dielectric Strength----Check

Check Insulator Thickness
This factor has special importance to class A insulators. If electric field strength exceeds the
endurance of dielectric material, breakdown occurs.
occurs. The higher the resistivity and dielectric
strength of the material has, the smaller thickness of insulator can be made economically.
Generally ESP operated under voltages of 50-12050 120 kV, for a 95% alumina porcelain insulator,
thickness of 15-20 mm is enough
ugh for normally working.
working
Shape and Geometry----Enough

Enough Electric Creep Distance
Make sure of the creep distance is the key point for a successful insulator design both for class A
and class B. Necessary creep distance is depending on the resistivity of the dust covered on the
resistivit (106 -cm), creep
insulator surface. Under dry state, for dusts with moderate high resistivity
distance can be calculated from 0.3-0.4
0.3 0.4 inches/kV. If condensation appears or the surface
pollutants are wet and sticky, longer creep distance
distance should be designed. Hot dry air blowing is also
necessary.
Umbrella
Umbrella is necessary only in case of insufficient creep distance. For vertical insulators downward
shape umbrella should be used and its inclined angle must be larger than the angle angl of repose of
dust. Distance between umbrellas should be as large as possible provided the creep distance being
enough. For horizontal insulators wave form umbrella is suitable with steep peak and wide bottom.
Enough Space Surrounding Insulator----

Insulator Avoid Corona Discharge or Flash Over
The necessary space surrounding insulator is related to the dust concentration and the spacing
between corona and collecting electrodes (distance S). Usually (1.1-1.5)
(1.1 1.5) S is acceptable. Larger
distance is necessary for higher dust concentration.

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Surface Conditions----Avoid
Avoid Dust and Condensation
Flat and smooth surface is beneficial to insulators that working in the dusty gas. Surface
condensation prevention should be also mentioned. Heating and hot air blowing are used
simultaneously or separately. Two methods of heating are used according to concrete conditions.
Outer heating is realized by heating coil or/and heating box; 1-3
1 3 kW is consumed for one insulator
heating Inner heating is realized by inserting a heating plug into the insulator body, simple and
energy saving (0.25 kW for one insulator).
4.6 General maintenance of insulators
Some of the regular maintenance know-how

know how of the insulators are as follows [8]:
a) Conduct regular check up on the insulators and heaters during shutdown period.
b) Keep the inner and outer surface dry and clean.
c) Use dry cloth and 70% alcohol for the cleaning of dusty insulators.
d) Replace the broken insulators with new one.
e) Check DE frame balance and alignment after insulator replacement.
f) Make sure all heaters/blowers are working properly.
g) Turn on the heaters around 8 hours before start up.
h) Ensure that all insulators are dry and clean before start up.
Figure 16. Cleaning insulators
Other effective remedy is the installation

i of purge air system,, which can protect and keep the
insulator clean, dry and prevent the sparking and arcing due to dust accumulation. It blows hot air
to insulator chamber, thereby preventing moisture and dust accumulation which in turn prevents
sparking and arcing. It also prevents insulator damage due to thermal stress or temperature
difference between the inner and outer surface.

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4.7 Self-Cleaning insulators
A high voltage insulator - working, in extremely difficult conditions - is one of the weakest elements
in ESP reliability [9].
Figure 17. Broken insulator process
In most solutions the cap of an insulator has two holes through which the atmospheric air is is
sucked into insulator and flows there near vertically
vertically with a velocity of about 1 cm/s. Such velocity
is not enough high to prevent the dust sedimentation on the the porcelain surface. For example: to
the sizing dust - gas channels v = 15 m/s is usually assumed [9].
The next disadvantage of present solutions is as follows: At the instable action of boiler burners, it
occurs, that the static gas pressure in ESP - being normally negative - reaches transiently positive
values. In this case the short return-flow
return of gas through insulators takes place.
As a result, some quantity of dust is emitted to the insulator chamber, causing the impurity both
inner and outer surfaces of insulators.
To avoid the disadvantages described above, a new concept of washing device was elaborated.
elaborated

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Figure 18. I) Tipycal oncept of self-cleaning.

s cleaning. II) New concept of self-cleaning
self [9]
Air, after being heated in the insulator chamber is dedusted in a ceramic filter, and then flows
through non-return
return valve and accelerating nozzle into insulator, being sucked by the negative
pressure in ESP. Every insulator maybe equipped with one or two nozzles [9].
[9]
Flowing out from nozzles, air is moving along a helicoidal trajectory near the inner surface of
insulator with enlarged velocity, removing sedimented dust and also preventing its sedimentation.
The flow acceleration in the nozzle depends on its shape and on the pressure
pressu difference available
[9].
Having, only a small space inside the insulator we must apply a short nozzle. Good effects were
obtained at de Laval type one, with a hole 10 mm dia. approximately [9].
4.7.1 Purge air system

In order to help the self-cleaning
cleaning mechanism, is common to use a purge air system.
system The purge air
heater is a combination of heater and air blower. It generates and provides high temperature air
flow to the insulator compartment in order to prevent the immediate change of the insulator
temperature when ESP is put into operation. It also maintains
maintains positive pressure inside the chamber
which can prevent dust from going up through the HV insulators. The heater generates the hot air
and the blower pushes the air flow through the heater, passing through hot air duct and is
delivered to insulator compartment [8].
Purge air heater reduces dust build up on insulator that can prevent electrical tracking on insulator
surface and insulator failure often caused by moisture and dirt. Moreover, purge air heater can
also help eliminate localized sparking, reduce humidity level and lower corrosion factors in ESP
internal component [8].

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Figure 19. Insulator heater [8]
Advantages of Purge Air Heater:
Short preheating time: Purge air heater requires only two to four hours before ESP start up
to ensure that temperature and moisture inside insulator compartment is in a proper level.
Protection of insulator: The purge air heater not only generates heat, but also helps
maintain clean insulator surface.
Convenient inspection and maintenance: It can be inspected and fixed during ESP
operation. No shutdown is required for its maintenance.
maintenance
Minimized inspection time: Moreover, the inspection period can be kept to minimum since
it is only one stop checking. It is not necessary to open all insulator compartments for
checking one by one.

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4.8 Evaluation of porcelain faults
Faults which may affect

ffect the function of the insulator shall not be repaired an further the
acceptance for repair shall be limited depending on the visual appearance. The defect surface shall
be free from cracks [10].
Figure 20. Completely broken insulator
Acceptable damages for repair are [10]:
a) Glaze defects, scratches and scraping in the glazing. Only faults which exceed the
requirements according to the relevant IEC publication
publication are repaired.
b) Smaller damages on the sheds. When the broken piece exists, the size of the damage must
be below:
Length = 10 % of shed diameter
Width = 5 % of shed diameter
Depth = 1.5 % of shed diameter
When the broken piece is missing the size of
of the damage must be below:
Depth = 1 % of shed diameter
c) Smaller damages on the porcelain body and smaller chips broken out from the flange
surface. The size of the damage must not exceed:
Depth = 3 mm for shed diameter > 500 mm
Depth = 2 mm for shed diameter < 500 mm

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4.9 Repairs
The repair must be done personnel with a good knowledge about the material used. The repaired
part shall be free from pores [10].
4.9.1 Repair of porcelain with the broken piece available

The damaged surface of the porcelain must be cleaned with ethyl acetate. The solvent used, must
be of a pure quality, with no grease residuals. Use clean clothes.
To attach a broken piece of porcelain use epoxy resin, e.g. CIBA GEIGY Araldite F (ABB material
number 1144 1101-107)
107) with hardener HY 956 (ABB material number 1261 0013-310).
0013
Mix 100 parts by weight (p.b.w) epoxy resin and 20 p.b.w. hardener (the mix shall
shal be used within
45 minutes).
Brush the adhesive in a thin layer on both surfaces. The joint is hardened under contact pressure at
room temperature for 15 hours or att 70 - 80 C for three hours [10].
Note: If the broken piece consists of several smaller porcelain pieces a polyacrylate adhesive can be
used e.g. Loctite 401.
After cleaning, brush the adhesive on one piece in a thin, covering layer. Place the two pieces in
exact position and handpress thee two pieces together for one minute. Excess adhesive is cleaned
off. If needed fill voids with epoxy paste, as described below [10].
Figure 21. Broken insulator

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4.9.2 Filling of chips and voids where the piece is missing

Procedure: Brown porcelain
The damaged surface must be cleaned with ethyl acetate.

This repair is made with epoxy resin, e.g. Araldite 121P, brown coloured paste (ABB material
number 1144 1015-503).
503). If necessary the paste
paste is mixed with Araldite colouring agent, DW 0133
(red) to get the colour of the porcelain.
The colour mix must be mixed with Araldite hardener HY 956 (ABB material number 1261 0013- 0013
310) mix ratio: 100 p.b.w. epoxy resin, 10 p.b.w. hardener and must be used u within 45 minutes.
The compound is applied in layers (1 - 5 mm) and can be held in position with tape.
After hardening at room-temperature
temperature for 15 hours or at 70 - 80 C for three hours, remove the
tape, was the resin surface clean and sandpaper the surface
surface smooth. Apply more compound if
necessary - sandpaper and clean the surface.
Apply with a brush a mix of polyurethane varnish and hardener (e.g. ABB material number 1176
1708-862
862 and material number 1261 0013-317).
0013 317). The mix ratio shall be two p.b.w.
p.b.w varnish and 1
p.b.w. hardener. Apply the varnish coating twice with hardening for two hours at room- room
temperature after the first coating and a finish hardening of , 24 - 48 hours or at 70 - 80 C for
three hours after the last coating [10].
Procedure: Grey porcelain
This repair is made with epoxy resin e.g. Araldite 2014 mixed with white epoxy paste, e.g. Araldite
DW 0131 to a light grey color.. The Araldite 2014 is a two component epoxy in a 200 ml cartridge
and is applied with a handgun with a mixer. Then mix with some blue paint paste e.g. Araldite DW
0135 to get the color of the porcelain.
The resin is applied in layers and can be held in position with tape.
After hardening at room-temperature
temperature for 15 hours or at 70 - 80 C for three hours, remove the
tape, wash the resin surface clean and sandpaper the surface. Apply more compound if necessary,
sandpaper and clean the surface.
Varnish with polyurethane in the same way as described for brown-glazed
brown glazed porcelain [10].
4.10 Glazing
The purposes of glazing are [6]::

Increase strength: Usually compressive glaze are covered. It means the expansion
coefficient of glaze is slight small than that of porcelain. If the blank and glaze match each
other suitable, the products strength can be increased about 30%.
Some surface defectsfects can be covered by glazing.
Increase capability of surface pollution prevention.

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So, it is no doubt beneficial for insulators long time working in atmospheric

atmospheric environment. But it by
no means the same thing for them working in gas with certain high temperature. In this case,
glazing not only useless, but also harmful. As temperature increases, tensile stress in glaze surface
increases also. We know glaze is a kind of brittle vitreous body without plastic strain, so more
mo will
occurs if tensile stress going higher. In this case, small particulates in the gas will enter into the
crevices hardly to remove away, hence reducing resistivity and insulation level. Surface
Surfa flash over
will easily occur and expanding the moirs, conducting burst of insulator. This is the main reason of
glazed support bushing of ESP bursting in China so far.
For insulators working in dust laden flue gas, it is better to select 85% or 95% alumina
al porcelain
with surface polished but without glaze.
4.10.1 Types of glazing

A large number of coatings based on inorganic or organic compounds have been developed and
applied to various porcelain insulators. Alternatively, there are plenty of insulator designs or
assemblies and substrate compositions, particularly comprising polymeric monolithic pieces or
polymer-based
based composites, which present protective properties against soiling and/or flashover
[11].
This document reviews

views the latest protective layers:
Semiconducting glaze
Hydrophobic coating
4.10.2 Semiconducting glaze

An electrical insulator having a coating of a semiconducting glaze may exhibit better electrical
properties than a conventional insulator with an insulating glaze. This is due to the fact that
a wet pollution deposit on the insulator tends to be dried off by the heat generated in the
semiconducting glaze layer due to a consequent leakage current which flows on the surface.
Thus, the use of porcelain insulators coated with semiconducting glazes may reduce flashover
faults caused by pollution or salt deposition [11].

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Figure 22. Difference

ifference between ordinary and conducting glaze
Example of conducting glaze
DURASSTOR is a Tin-oxide
oxide system glaze including niobium oxide. Current flowing through
semiconducting glaze produces:
Surface drying effect by Joule's heat
Uniform (resistive) voltage distribution
Patents of semiconducting glaze
Table 12. Patents of semiconducting glaze [11]

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4.10.3 Hydrophobic glaze

When dry salts present on the insulator surface are wetted, a conducting electrolyte is formed and
flashover occurs. When a hydrophobic surface is available, water
w ter forms beads due to the low
surface energy and a continuous conducting film is prevented to be formed. A variety var of
hydrophobic surfaces have been fabricated from organic polymers to inorganic materials [11].
Figure 23. Hydrophobic process
Example of hydrophobic coating
RTV covering PPC manufactured insulators with a silicone layer will combine the porcelains
undisputed superiority of high mechanical strength as well as its longevity due to inorganic
material with the composites excellent behavior in areas with excessive pollution.
pollution. The insulators
hydrophobic surface is combating negative effects of contamination and is enhancing the electrical
insulation characteristics and low leakage currents in highly polluted areas [12].
[12]

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Patents of hydrophobic coatings
Table 13. Patents of hydrophobic coatings [11]

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5 Type of electrodes
5.1 Discharge electrode
Over the years, the discharge electrode has taken many different forms, from a simple round,
square or barbed wire, through to so-called
so called controlled emission electrodes for specific duties,
some units being claimed as 'unbreakable'. As a modern precipitator can contain the equivalent of
50 km of wire electrode, the cost, in a competitive bid situation, means that a simple readily
available shaped material can offer an economic advantage, so a round wire formed into a spiral or
twisted square section wires can
n often be found in many installations [3].
Figure 24.. Types of discharge electrodes [13] [14] [15] [16] [17] [18]
a) RDE-1
b) Barbed tape
c) RDE-2
d) RDE-3
e) Barbed tape
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f) Pipe and double-spike

spike electrode
g) Spiral electrode
h) Spike band
i) Pipe and double-spike
spike electrode
j) Pipe and double-spike
spike electrode
According to Maria Jedrusik, thehe results obtained from the tests carried out in laboratory-scale
laboratory ESP
and in industrial conditions have shown that special construction of of ESP discharge electrode has to
be used as well as the optimization of electric supply parameters and energizing method (taking
into consideration the physical characteristics and chemical composition of fly ash) has to be
carried out for the efficient collection
llection of low-resistivity
low resistivity fly ash coming from coal fired stoker boilers.
Analysis of the collection efficiency measured in laboratory scale ESP for various fly ashes has
shown that [13] [14] [15] [16] [17] [18]:
Proper selection of discharge electrodes for specific fly ash properties leads to higher
collection efficiency.
For the same discharge electrode construction the influence of physical and chemical
properties of fly ash on collection efficiency appears clearly, for example, for high resistive
fly ashes with high contents of fine particles
particles a barbed tape electrode is more effective than
the spiral one.
An increase of the number of particles larger than 100 m m (samples P-1
P and P-17 in this
specific case) in fly ash decreases the maximal obtainable level of collection efficiency.
Particles of this size are easy to charge and its collection is possible even at low supply
voltage levels. An increase of supply voltage does not improve significantly the collection
efficiency, and sometimes, at certain conditions can even decrease the efficiency.
efficiency
For fine particles, the collection efficiency can be increased via increasing supply voltage,
however, some measurements indicate that the optimal voltage (for example about 50 kV
for the sample P-2)2) can exist, for which the collection efficiency is the maximal. There was
also noticed that a relatively high content of unburned coal (comparing to fly ash with large
particles) does not worsen the collection process. This effect may suggest that more
important in the precipitation process is the size of individual
individual particles than their chemical
composition, mainly because fine particles are not easily re-entrained
re entrained from the collecting
electrode.
5.2 Collecting electrodes
Over the years, the collector like the discharge electrode has taken many different forms, from an
initial simple flat or corrugated plate to the present large fabricated designs [3].
During the 1950s and 1960s, there was a vogue for so-called
so 'catch pocket' profiles where, in
theory, the dust, upon being dislodged by the rapping, passed through the pocket into a vertical
quiescent zone, such that re-entrainment
entrainment was minimized [3]. In practice, as the pockets caused

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local electric field disturbances at the surface, and the maximum field was at the pocket, this
resulted in the greatest dust deposition adjacent the pocket, so that when rapped, the dislodged
dust tended to fall outside the protected area. Their use has been discontinued; not only was the
theory unsound, but mainly because of cost, since to provide
provide the quiescent zone, the collector
plate comprised two separate sheets.
Most installations today, which can have collector plates up to 5 m by 15 or 16 m high, employ
either full-height cold-rolled
rolled strips having inbuilt stiffening ribs, joined together to form the
collector, or alternatively, some type of fabricated collector, employing pressed or rolled sheets
connected between vertical stiffening members, e.g. channels. These approaches (Figures 4.5 and
4.6) have been found to provide the requisite mechanical
mec strength and stability to maintain the
degree of electrode/collector alignment necessary to meet the low emission levels presently
demanded. Particularly, so as to minimize costs, collector metal thicknesses are typically around
1.5 mm, which without ut the stiffeners, would be totally unsuitable [19].
Figure 25. Types of collecting plates
The actual profile of the collector depends on the availability of fabricators to produce a suitable
profile in the lengths and tolerances required. Each supplier will have a preferred profile for his
particular cold-rolled sheet, but essentially all forms have raised upstands at each edge and various
stiffening rib arrangements to balance out rolling stresses, such that twisting or 'banana-ing' is
eliminated. Some have slots and fingers built into the edge stiffeners, which interlock, to provide
additional stability and alignment.

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6 Anticorrosion coating of discharge electrode
The problem of corrosion protection of electrostatic precipitators used in the energy industry,
during its construction or modernization is of vital importance. Several months construction period
and the period of time elapsed from the end of construction to operation
peration promotes corrosion of its
components. Significant impact on the electrical parameters of an electrostatic precipitator
performance has the corrosion phenomena of its emission components, which are the corona
electrodes. Manufacturers do not apply any corrosion protection coating on electrostatic corona
electrode for fear of worsening their emissivity. This paper presents the results of comparison of
emission properties of corona electrodes with and without corrosion protection coatings. Rode and
mast
st type electrodes were studied. The analysis of the results was performed using a statistical
method based on the time-series
series model. The obtained results clearly show that the use of anti-
anti
corrosion coating does not impair the electrical parameters of corona corona electrodes. Corrosion
protection can be used both during the modernization as well as during the construction of new
electrostatic precipitators.
Currently built electrostatic corona electrodes are made of general purpose construction steel. The
use of steel with high corrosion resistance is not desirable due to financial reasons. Despite the
problems arising from the corona electrode corrosion, producers do not protect them by applying
anticorrosion
corrosion coatings containing a rust inhibitor. This is due to the fear of the danger of
electrostatic precipitator working disturbance caused by changes in the electrical parameters of
corona electrodes coated with high resistivity coating. This study aimed to determine the influence
of corrosion protection coatings of the corona electrode on their electrical parameters.
Consequently, they should give the answer
ans er whether the effect of the corrosion protection is so
unfavorable that prevent its use.
The most important parameters characterizing the electrical corona electrodes

ctrodes are:
are
Current-voltage
voltage characteristics, and initial corona voltage determined on its basis.
Current density at the surface of collecting electrode.
The first parameter, defined as the emissivity of the electrode, provides the intensity of the electric
elect
field produced by the corona electrode. Electric field strength influences the time of obtaining the
charge by the dust grains allowing the migration and deposition on the collecting electrode. The
second parameter affects the mechanical properties of the deposited dust layer on the surface of
the electrode.
6.1 Study about non-metal

metallic coatings
The study involved 5 cylindrical electrodes, in the form of rods of = 6 mm made of steel S275 and
four mast type electrodes. Carrying mast of the electrodes on the study, was made of steel pipe
with a diameter of = 10 mm. Emission elements made of steel strip were welded at equal

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intervals. The essence of this type of electrode structures is the presence of tips with a small radius
of curvature being the source of the corona [20].
The study also involved 4 different coatings [20]:

Acrylic Resin
Unikor C
Polyurethane varnish
Acrylic Resin + Fe2O3
The results of the research are [20]:

[20]
Graphic 1.. Voltage-current

Voltage current characteristic for several coatings

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Graphic 2. Current density-discharge electrode side
Graphic 3. Current density-colecting plate side

The results of measurements of the current density distribution on the collecting electrode in case
of spike electrode without coating and with anticorrosion
anti corrosion coatings are shown in Figure 4.

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The results of analogous measurements corresponding to a cylindrical electrode (having a diameter

of = 6 mm), are shown in Figure 5. For these electrodes, the differences in a current density
depending on the presence and the type of anti-corrosion
anti corrosion coating are much more visible than in
the case of a spike electrode [20].
Influence of the coating with filler in the form of iron dioxide (III)
(III) on the electrical parameters of
the discharge electrode, it was confirmed by introducing into the waterborne anticorrosive
formulation, 15% by weight of Fe2O3. The measurement results confirmed that the presence of
iron dioxide (III) in the coating, applied
applied to the surface of the discharge electrode, significantly
changes its electrical characteristics by increasing the emissivity [20].
Effect of the presence of the iron oxide (III) as a filler in the coating on the electrical
electrical parameters of
corona electrode was studied by applying water-based
water anti-corrosion
corrosion paint filled with 15 wt.%
Fe2O3. The results confirmed that the presence of iron oxide (III) in the coating applied to the
corona electrode significantly changes its electrical characteristic by increasing the emissivity [20].
The test results show that the use of anticorrosion coating with the filler in the form of dioxide of
iron (III), does not worsen of the emissivity parameters of corona electrodes protected from
corrosion, but even increases it. One can assume that this is due to the physicochemical properties
of the compound, but the cause of this phenomenon has not been determined. A different
situation occurs in the case of rod
od electrodes secured by a polymer coating (polyurethane resin)
[20].
The intensity of the corona discharge of rode type electrode dependents on the radius of curvature
laye (~ 50 m),
of the electrode. It is believed that the thin layer m), applied by spraying has local
discontinuities or areas with a lower thickness, which are the source of the corona. This increases
the emissivity of the rod electrode similar to the spike electrodes, having blades with a small radius
of curvature.
re. That interpretation is borne on the electrical properties of polyurethane polymers
such as high value of the resistivity [20].
6.2 Metallic coatings
The electrical conductivity of contact materials can be largely reduced by corrosion and in order to
avoid corrosion, protective surfaces must be used. There are basically two groups of materials,
which can be employed for corrosion protection of electrically
electrically conductive surfaces. The first group
includes noble metals such as gold, silver and palladium. The second group comprises of corrosion
resistant so-called
called passive metals such as tin and nickel. These metals are basically ignoble and
they derive their corrosion
orrosion resistance from the presence of a thin oxide film on the surface, called
the passive film, which acts as a protective barrier between the metal and its environment. The
passive film inhibits deeper corrosion, and is usually an oxide or nitride with a thickness of
nanometers.. Corrosion protection of passive metals is limited to certain conditions, which are
applied to many working environments of electrical contacts [21].
Below there is an overview of corrosion resistances

resistances of the most common used coating materials for
electrically conductive surfaces [21]..
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Table 14. Main metallic coatings [21]
Two alternativee coating methods are applied [21]:

Electroplating process
Hot-dipped
dipped tinning process
Comparison
omparison of selected applications
Mechanical Properties: In general hot-dipped

dipped tinned coatings tend to have higher surface
hardness and higher abrasion strength compared to electroplated coatings [22].
Thermal Properties: Due to missing chemical ingrediences hot- hot-dipped tinned surfaces
practicly doesn`t show outgasing phenomenons, bubbeling or separation tendencies in
higher temperature ranges [22].
Chemical Properties: The surface of hot-dipped
hot dipped tin coatings has no caves and possible holes.
Missing ingrediences tends to an excellent resistance against chemical stress (steam aging
test etc.). Due to the specific design of electrolytic capacitors hot-dipped
hot dipped tinned lead wires
showed superior characteristics in regard to chemical resistance [22].
[22]
Solderability Properties: Both, concentric hot-dipped
dipped tinning (FOV) and tin-electroplating
tin
lead to solderability in accordance with aging-
aging and solderability-tests
tests (DIN IEC 68 Part 2) and
both comply with class V5 (DIN 40500 Part 5). The thickness ickness of the tin coating has to
depend on the range of the thermal stress under production, on the estimated growth of
the intermetallic layer, on the mechanical surface conditions of the wire, or the used tools
for handling the wire. Whenever high pull strength of soldered connections between
component and lead wire is needed, hot-dipped dipped tinned wires showed significant results
[22].

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6.3 Composite discharge electrode
Electrically conductive polymer composites can be highly advantageous in corrosive applications.

Conductive polymers can be made by adding in small volume fractions of carbon nanofiber into the
mix before processing. The carbon will not significantly change
change the mechanical properties, but it
will enhance the electrical properties suitable for certain applications where conductivity is
required [23].
The typical electrode is made out of steel, making it heavy and highly susceptible
susceptib to corrosion
failure over time. Corrosion resistant steels are very expensive. Polymers are corrosion resistant
and cheap; however, polymer materials are not electrically conductive. The objective (using
electrically polymers) is to produce a composite electrode that will be suitable in strength, lighter,
adequately conductive, and more corrosion resistant than the current steel electrode [23].
Electrically conductive polymer composites can be very useful in working environments

environm that are
too corrosive for typical metals. An example that has been discussed is the electrostatic
precipitator, which is widely used by the power industry to remove particulates and mist from flue
gases. The gases can be highly corrosive, which leads to the use of expensive metal alloys such as
hastelloy. The use of metal alloys also requires expensive structural support for the structures.
These problems can be alleviated by the use of a conducting polymer composite [23].
To make a conducting polymer, carbon nanofibers can be used as an additive in small volume
fractions. When the volume fraction of the nanofiber is small, the nanofiber may not provide much
enhancement of the mechanical strength; but the electrically conductivity
conductivity can be improved
significantly. However, producing a composite with nanofibers requires careful processing steps
because the stiff nanofibers must be dispersed without significant breakage. If the fibers are
broken due to the mixing action, the reduction
reduction in fiber length can significantly reduce the
conductivity because the shorter fibers may not provide a continuous path for the flow of electrons
[23].
For this project, it was necessary to design and construct an ESP chamber
chamber to conduct tests on
sample discharge electrodes using electrically conductive composite materials for the rod or
backbone of the electrode, and in some cases for the discharge tip of the electrode itself [23].
Iten Industries (Ashtabula, Ohio) produced sample hollow rods containing small volume fraction
amounts of conductive carbon nanofibers produced by Applied Sciences, Inc., in Cedarville, Ohio.
The rods were shipped to Ohio University and used to construct some of the sample discharge
electrodes. The rods were first cut to a six inch length. Next, three stainless steel ninja stars were
pressed onto the outside of the rod, and fixed using a conductive epoxy. To attach the rod to the
test chamber, and to attach the high voltage supply cable, a nut welded to a washer was fixed to
the top of the rod by conductive epoxy; therefore, creating a conductive path from the top of the
rod to each of the stars. Iten produced several rods containing different amounts of nanofiber
nanofib to
test the lowest threshold of conductivity required to allow the ESP to function. Several other
electrodes were constructed using solid carbon rods as backbones, and different conductive
polymer materials as discharge tips to test various other combinations
combinations for use in ESPs. All
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electrodes were assembled similar to the above example. The sample descriptions are provided
below in detail [23].
Sample 001 was constructed entirely from 316 SS, rod and stars, welded together. ThisT sample is
the base electrode against which all sample composite electrodes will be tested. In addition, two of
these were also used as the pre-chargers
pre [23].
Figure 26. Sample 1
Sample 002 was constructed from a pultruded conductive hollow rod made by Iten Industries. This
rod had a resistivity of 80.12 Ohm-cm.
Ohm Stainless steel 316 stars were fixed to the rod by light press
fit, and conductive epoxy. A steel washer with a welded nut
nut was also attached via conductive epoxy
for mounting the sample to the ESP setup [23].
Figure 27. Sample 2
Ohm Stainless steel 316 stars fixed to the rod by light press fit,
and conductive epoxy. A steel washer with a welded nut was also attached via conductive epoxy
Figure 28. Sample 3
fit, and conductive epoxy. A steel washer with a welded nut was also attached via conductive epoxy

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Figure 29. Sample 4
rod had a resistivity of 96.37 Ohm--cm. Stainless steel 316 stars were fixed to the rod by light press
fit, and conductive epoxy. A steel washer
washer with a welded nut was also attached via conductive epoxy
Figure 30. Sample 5
fit, and conductive epoxy. A steel washer with a welded nut was also attached via conductive epoxy
for
or mounting the sample to the ESP setup [23].
Figure 31. Sample 6
Sample 007 was constructed from a solid carbon rod with carbon fiber matt used as discharge tips.
The fiber matt had no resin, and it was sandwiched between polypropylene discs to hold its shape.
Is was assembled using white PVC rods as spacers, and fixed with conductive epoxy [23].
Figure 32. Sample 7

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Sample 008 was constructed from a solid carbon rod and carbon plate disks. The disks were cut
with a hole saw out of a carbon plate obtained from the Composite Store (item #C4063, Tehachapi,
California). It was assembled using white PVC rods as spacers, and
and fixed with conductive epoxy
[23].
Figure 33. Sample 8
Sample 009 was constructed from a solid carbon rod with carbon plate laser cut into star
configuration. The carbon plate was obtained from the Composite Store (item #C4063, Tehachapi,
California). It was assembled using white PVC rods as spacers, and fixed with conductive epoxy
[23].
Figure 34. Sample 9
Sample 010 was constructed

tructed from a solid carbon rod with carbon matt sandwiched between white
PVC spacers, and fixed with conductive epoxy [23].
Figure 35. Sample 10
To summarize, each of the composite discharge electrodes which were tested against the base
stainless steel discharge electrode did at least as good, or better in their respective collection
efficiencies.

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Graphic 4. Collection comparison [23]
VI curves for each of the composite electrodes, including the base stainless steel electrode
Graphic 5. Voltage-current comparison [23]
This testing verifies that conductive polymer composites could be used to replace current steel
discharge electrodes in a commercial electrostatic precipitator application. Composite electrodes
that were adequately conductive, and more corrosion resistant than the current steel electrode
were designed and tested [23].

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The results here should only be considered as a strong positive basis for the concept of introducing
conductive composites for use as
as the construction material for discharge electrodes in commercial
ESPs. The next step should be constructing a small scale number of commercial size electrodes for
implementation into a pilot level ESP for long term study [23].
The results for carbon fiber composite discs and carbon fiber mats as discharge electrodes were
particularly impressive. These materials should be tested further [23].

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7 Conclusions
One of the key constrains in ArcelorMittal Group ESPs is a lack of reliability due to the difficulty of
the technique.
In this Guideline, it is tried to be explained how to solve some critical constrains refered with ESP,
like corrosion, design modifications and sealing.
These dry ESPs for iron and steel applications are exposed to gas and process variables conducive
to the formation of corrosion products. High moisture content of the gas stream coupled with
varying temperature conditions provides fertile ground for the control of corrosion. The use of iron
ore or waste materials provides an ample source of chemical constituents that can form acidic
conditions with excursions below dew point levels.
Although corrosive
rosive conditions and corrosion problems in varying degrees are facts of life in the
practical application of many electrostatic precipitators, good design and proper maintenance with
an understanding of common corrosion processes and preventive measures.
After reviewing all information available to solve these constrains identified by several inspections,
this Guideline can provide some techniques in order to keep the equipment with long life in
industrial service.

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8 Bibliographic references
[1] R. A. Yeske, "Review of corrosion in electrostatic precipitators," The Institute of Paper

Chemistry, 1986.
[2] H. J. H. \.. J. Katz, "Corrosion problems and solutions for electrostatic precipitators,"
Journal of the Air Pollution Control Association, 1976.
[3] K. Parker, Applied Electrostatic Precipitator, 1997.
[4] T. \.. Chyun, "Double Access Door," Tai \& Chyun Newsletter, 2013.
[5] P. E. Mix, Introduction to non destructive testing, 2005.
[6] L. Tao, "Technical and economical comparisons between different kinds of materials
and different geometries for electrostatic precipitator insulators," Icesp X, 2006.
[7] L. Tao, "How to eliminate ESP insulator thermal breakdown and insulation aging,"
Icesp IX, 2004.
[8] T. \.. Chyun, "Enhancing Electrostatic Precipitator Performance," 2014.
[9] M. Koralun, "Improved cleaning of high voltage insulator in ESP," 6th International
Conference on Electrostatic Precipitation (VI ICESP), 1996.
[10] ABB, "Repair of damaged porcelain insulator," Product infromation.
[11] D. Hotza, "Protective Coatings for Porcelain Insulators," Recent Patents on Corrosion
Science, vol.ol. 2, no. 1, pp. 22-29,
22 2012.
[12] P. Insulators, "The very best," Brochure.
[13] M. Jedrusik and A. Swierczok, "Experimental test of discharge electrode for collecting
of fly ash of different physico-chemical
physico properties," 2006.
[14] M. Jedrusik, A. {\'S}wierczok
'S}wierczok and A. Jaworek, "Collection of low resistivity fly ash in an
electrostatic precipitator," in Journal of Physics: Conference Series,
Series 2013.
[15] M. Jedrusik and Swierczok, "Design efficiency of ESP," Air Pollution--Monitoring,
Pollution
Modelling, Health and Control? Intech, 2012.
[16] M. Jedrusik and A. Swierczok, "The influence of fly ash physical and chemical
properties on electrostatic precipitation process," Journal of Electrostatics, vol. 67, no.
2, pp. 105-109, 2009.
[17] M. Jedrusik, J. B. Gajewski and A. J. {\'S}wierczok,
{ 'S}wierczok, "Effect of the particle diameter and
corona electrode geometry on the particle migration velocity in electrostatic
precipitators," Journal of electrostatics, vol. 51, pp. 245-251,251, 2001.
[18] M. Jedrusik,ik, A. Swierczok and R. Teisseyre, "Experimental study of fly ash
precipitation in a model electrostatic precipitator with discharge electrodes of different
design," Powder technology, vol. 135, pp. 295-301, 2003.
[19] K. Parker, Electrical Operation of electrostatic precipitator, 2007.
[20] R. Machnik, "Effect of anti-corrosion
anti corrosion coatings of corona electrodes on selected
operating parameters of industrial electrostatic precipitator," Eksploatacja i
Niezawodnosc, vol. 16, no. 1, p. 56, 2014.
[21] J. Song, L. Wang, A. Zibart and C. Koch, "Corrosion Protection of Electrically
Conductive Surfaces," Metals, vol. 2, no. 4, pp. 450-477, 2012.
[22] G. Burstner and E. Frohlich, "Electroplating versus hot-dipped
hot dipped tinning. A comparison of
application experiences,"
iences," Carts Europe, pp. 17-23, 1997.
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[23] J. M. Morosko, "Composite discharge discharge electrode for electrostatic precipitator,"

2007.
[24] M. Jedrusik and A. Swierczok, "The influence of the discharge electrode shape on the
efficiency of electrostatic precipitator," in The 9th international conference on
electrostatic precipitation. Mpumalanga,
Mpumalanga 2004.

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First Pack of Solution For ESPs Improvement

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First pack of solutions for ESP improvement: corrosion, isolation,

Project ESP improvement

Authors Virgilio Garca, Francisco Voces

2014 ArcelorMittal All rights reserved for all countries

2 Corrosion in ESP ................................................................................................

3 Thermal insulation ................................................................................................

4 Electrical Insulators ................................................................................................

4.8 Evaluation of porcelain faults ................................................................

5 Type of electrodes ................................................................................................

6 Anticorrosion coating of discharge electrode .....................................................

8 Bibliographic references ................................................................

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There has, in recent years, been an increasing awareness and world-wide

The features of the electrostatic precipitation process,

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1.1 Summary of contents

Many key issues are going to be faced below:

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SO3 + H2O -> H2S04

2.2 Types of Corrosion

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Briefly, the various types of corrosion may be summarized as follows [2]:

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2.3 Critical Areas of Corrosion Attack in Precipitators

2.3.1 Outer Shell Walls

Figure 1. Corrosion in outer Shell near to TR.

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Figure 2. Roof corrosion

2.3.3 Collector Plate Surfaces

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Figure 3. Collector plate corrosion

2.3.4 High Voltage System

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2.3.5 Hopper Areas

2.3.6 Access Doors

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Figure 4. Access door corrosion, inside view

2.3.7 Discharge Electrode

Figure 5.. Dust accumulation on the discharge electrode surface

Lambda sensor Zirconium oxygen analyzer

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Low thermal conductivity

Rockwool panels prices

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3.1.2 Seal gaskets

Trend Material T (C) PH Pression

Aidmerptfe 7612R PTFE exp. -288 a 316 0 14 30 Mpa

Below, there is a list of some prices of seals from SEAL SALES-PTFE:

Size Prize ($)

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Figure 6. Seal installation

Figure 7. Corroded seal

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3.1.3 Access door

Figure 8. Double door

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Figure 9. Insulation between indoor and outdoor in double doors

Typical Installation Instructions of a double door

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3.2 Leakage detection

3.2.1 Non destructive testing methods

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NOTE: According to many experts, high