LANCO ANPARA POWER LIMITED

2×600MW, ANPARA, SONEBHADRA (U.P.)

ESP+FF

Operating and Maintenance Manual

ZHEJIANG FEIDA ENVIRONMENTAL ENGINEERING CO., LTD

 Contents
1. Summary
1.1 Introduction

1.2 Design condition and environmental condition

1.3 Mainly modified content

1.4 Working principle and technical performance of ESP+ FF combined dust collector

1.5 Basic configuration and structure of ESP+FF combined dust collector

1.6 Control, monitor and alarm equipment

1.7 Ash removal system

1.8 Equipment’s start-up and shut-down

2. Maintenance instruction
2.1 Summary

2.2 Maintenance purpose

2.3 Maintenance sequence

2.4Requirement of Maintenance personnel

2.5Ordinary maintenance

2.6 Breakdown maintenance

2.7 Filter bag replacement

3. Operation instruction
3.1 Summary

3.2 Measures before start-up

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3.3 Start-up

3.4 Inspection during the operation

3.5 Shut-down

3.6 Special measures

3.7 Breakdown alarm

4. Erection specification
4.1 General specification

4.2Special specification

4.3Working in the FF

4.4 Overhauling the damper

4.5 Countermeasures when FF breaking out of fire

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Summary
1.1 Introduction
This manual is suitable for ESP modified to ESP+FF dust collector of India aluminium 600MW
unit.
This manual is suitable for all relevant personnel to read, especially the relevant personnel of
equipment running and maintenance, this is helpful for them to understand how this equipment
works, how to discover and eliminate the breakdown and how to maintain.

1.2 Design condition and environmental condition

1.2.1 System profile

Technical parameter of the boiler

Boiler model and manufacturer: This boiler is a subcritical pressure, natural circulation, Π
type coal-fired boiler, which adopts front and back wall convection combustion, single
furnace, once reheat, balanced draft and dry ash extraction. DONGFANG BOILER GROUP
CO., LTD. is its manufacturer.

Consumption of designed coal：379.37t/h；

Consumption of checked coal：464t/h

1.2.2 Coal analysis

Mar %
12.0 14.5
Aar %
34.1 40
Var %
24.6 20.3
Cad %
29.3 25.2
Qgr,ar Kal/kg 3800 3200
HGI
50 60
（R90） %
18 18
Car %
38.0 31
Har %
3.3 3.2
Oar %
11.1 9.9

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 Nar % 0.9 0.85
St,ar % 0.6 0.55
Ash % 34.1 40
DT ℃
ST ℃
FT ℃
SiO2 %
48.58 54.58
Al2O3 %
21.14 25.21
Fe2O3 %
24.75 13.35
TiO2 %
1.50 1.40
SO3 %
0.58 0.89
P2O5 %
0.61 0.32
CaO %
1.38 1.88
MgO %
1.73 2.03
%
Nil 0.11

1.2.4 Designed gas volumn for one boiler: 1200000m3/h

1.2.5 Inlet gas temperature: 127℃～147℃.
1.2.6 Inlet dust load: Designed coal 73624.2 mg/Nm3, checked coal 98497.7mg/Nm3
1.2.7 Efficiency of dust collection: ≥99.9％; Emission concentration: ≤50mg/Nm3
1.2.8 Resistance: ≤1200Pa (Including electric area)
1.2.9 Air leakage percentage: ＜2.5％

1.3 Working principle and technical performance of ESP+ FF combined dust collector
Definition of ESP+FF combined dust collector

ESP+FF combined dust collector complexly utilizes and organic combines the dust removal
advantage of ESP and FF. It is a combined high efficiency dust collector that most dust of the gas is
collected in the electric fileds, then the rest fineness dust is to be collected in the FF. It has the
advantage of stable dust collecting and outstanding performance.
Principle of operation
Based on the ESP+FF principle of operation, organic combines the advantage of the ESP and
FF: the front electric fields pre-collect ≥ 70-90% dust; the rest dust is to be collected by the rear FF
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device. Meanwhile, the pre-dust collecting and charging function of the front electric fields plays an
important part in increasing the ESP+FF performance.

Pre-dust collecting function of the electric field

① Pre-dust collecting reduces the dust load of the filter bag that is reducing the rising rate of the
resistance.
② Pre-dust collecting prolongs the ash removal cycle of filter bag, saves the energy consumption
and prolongs the service life of the filter bag.
Technical performance
1.it’s suitable for the high dust resistivity collecting; the collection efficiency is high and stable.
Collection efficiency of ESP+FF will not be influenced by high resistivity of the fine dust, coal type
and ash character, the emission concentration can easily reach ≤50mg/Nm3 and long-term stability.
2. The operation resistance will be 500Pa less than pure FF, it can reduce the power consumption of
the ID fan.
3. Long ash removal cycle and small energy consumption of gas supply.
Due to small dust collection of the filter bag, the resistance rise is slow, its ash removal cycle is 2
times more than pure FF, the compressed air consumption is not to be 1/3 of pure FF.
4 Prolong the service life of the filter bag.
（1） Low operation resistance and small pressure difference of the filter bag load prolong the
service life of the filter bag.
（2）Long ash removal cycle and few times of ash removal prolong the service life of filter bag.
（3） The ESP+FF service life is 2～3 longer than pure FF under the same operation condition.

1.4 Basic configuration and structure of ESP+FF combined dust collector

1.4.1 From the function, the ESP+FF can be devided into:
11. The front ESP 2.The rear FF 3.Monitoring function 4.Protection function 5.Electrical
control
A) The composition of the front ESP is same as the regular ESP.
B) The composition of the rear FF is filter bag, cage, ash removal system, lift valve and
compartment casing.
1）Structure of filter bag: Outside-filter type round bag, elastic bag mouth should be seal
tightened with bag plate.
2）Structure of bag cage: Up and down section structure.
3）Ash removal system: Pulse injection structure.
4）Lift valve: Up and down lifting structure.
1.4.3 Structure characteristic of ESP+FF combined dust collector
The front ESP + the rear FF are laid in the same casing; guiding device-the patented technology
designed by FEIDA should be adopted between the two-part dust collections. It has the advantages
of mature technology and easily maintenance.
1.4.4 The retrofit part of ESP
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1.4.4.1 CE system
CE system is composed by CE suspension device, CE plate and other parts. CE plate is the
collecting electrode; it is shaped by stressing the thin plate on the special stress. The CE plate in this
item is the original one.
1.4.4.2 DE system
DE system is one of the ESP key parts; it is composed by DE suspension, frame, DE wire and
other parts. DE wire is the discharging electrode.
1.4.4.3 CE rapping
Rapping device is an important device of ESP, the dust which accumulated on the plate and
wire will be fallen into the dust hopper by rapping.
CE rapping uses the original top electromagnetic rapping.
1.4.4.4 DE rapping
DE rapping also uses the original top electromagnetic rapping.
1.4.4.5 Inlet nozzle
Inlet nozzle is the connection and transition section between the inlet duct and ESP casing. Air
flow distribution is installed in the inlet nozzle, the purpose is to let the passing dust-load gas which
from the duct to get into the whole electric fields evenly. Because the speed of the air flow in the
nozzle reduces gradually, some big dust particle will be naturally subsided
1.4.4.6 Casing
Casing is composed by the column, side panel, end panel and bracing, is the stress support of
the ESP steel casing, it composes an airtight container with the front and rear inlet nozzle, roof, dust
hopper, bag plate and nozzle house.
1.4.4.7 Dust hopper
The accumulated dust on the plate and wire drops into the dust hopper when rapping, and then
discharged out by the ash removal system. The level indicator is installed in the dust hopper, the
alarm system will send out the acousto-optic warning when the accumulated dust in the hopper
passes this height, then it should be processed promptly. The excessive dust in the hopper may
damage the important part seriously, such as the plate electrode. Once the load passes the actual
bearing capacity of the dust collector, it will also cause the major accident, so it should be careful.
1.4.4.8 Electrical part
The ESP electrical part is composed by the high voltage direct-current power supply (including
the control system) and low voltage control system.
a) High voltage power supply uses the present conventional type: GGAJ02 type. Generally
this equipment includes the high voltage rectifier transformer, automatic control cabinet and
reactor, or high resistance rectifier transformer and automatic control cabinet.

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 This equipment can rapidly change and adjust the voltage of the electric field according to the
gas condition of the electric field; it can adjust the spark frequency of the electric field according to
the current feedback signal, that cause it works in the optimum condition and reach the best
collection effect.
This equipment has the quite perfect interlock protection system.
b) Low voltage control system and its function:
 DE and CE rapping program control;
 Heating and the temperature control of the high voltage insulation;
 Level indicator detecting and alarm control;
 Ash discharge and ash transport control;
 Safety interlocks control of door, hole and cabinet;
 Electrical heating function of the dust hopper;
 Temperature detects and display of the inlet and outlet gas.
 Integrated signal display and alarm device.
Note: To choose the above function according to the need.
1.4.5 FF part
1.5.1 Structure characteristic
1）Low voltage long-bag struction is mature.
2）Compartment structure, the off-line and online ash removal can be switched。
3）OPTIPOW pulse valve is adopted to guarantee the high efficiency, stable and reliable of the
ash removal.
4）It can prevent the filter bag burning and sticking under the condition of high temperature gas and
lampblack in it.
1.4.2.3 Air flow equispaced structure
1）Effect：it causes the even distribution of the flow speed and gas when it passes the electric fields
and the filter bags.
2）Structure: the special patented technical structure
1.5.2
Each dust collector separates into two lines, 6 air tanks and 12 outlet dampers for each line, each line
equips with 7 bypass dampers and 1 seal fan of bypass damper. The system adopts high nozzle house
configuration, you can get into the nozzle house to exchange the filter bag and cage directly through
the access door. A 100% gas volumn bypass duct is designed on the top of the dust collector, the gas
gets into the bypass duct through the ESP area, seal valve bypass duct with zero leakage is laid to
satisfy the filter bag protection request when the gas condition is abnormal.
Pulse valves of the air tank are connected to the injection tubes, an injection tube does the ash
removal for a row of filter bag. The length of the filter bag is 8 meters, the top of the filter bag is
equipped with the special stainless elastic ring, so the filter bag can be reliably fixed on the bag plate
hole without using the tool. The cage which is made by the steel wire is installed in the filter bag, the
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cage is composed by the up and down section.
The dust collector is also equipped with the electric control equipment for the PLC ash removal,
please see part three “Operation Instruction”for details.

1.6 Control, monitor and alarm equipment

The operation of the equipment is controlled by PLC through the temperature, pressure,
differential pressure, current, voltage and the travel feedback signal, and monitored by the PC. Some
equipment prompts the alarm message through the indicator light and acoustic equipment.

1.7 Ash removal system

Differential pressure control mode can well maintain the system resistance to be dynamic stable,
it is propitious to reducing the senseless injection, it is also propirious to saving the energy and
protecting the filter bag, so FF always adopts the differential pressure control mode to cleaning the
ash.

Reducing valve

Pulse valve

Air tank

Injection tube
Pressure of air tank
Differential pressure of dust collector

PLC

Control room

控制室

Under differential pressure condition, when the differential pressure of the dust collector
surpasses a setting value, PLC will transmit a signal to the pulse controller, then the pulse valve will
open, the compressed air in the air tank will instantly release and enter into the filter bag. The dust
cake accumulated on the outside will break and get loose and then drop into dust hopper when the
filter bag expands.
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 If the differential pressure was still very big after a row of filter bags was ash cleaned, then the
same ash removal way will be done to another row of filter bag at the shortest interval of 10 seconds.
The ash removal order will not stop until the differential pressure of the filter bag drops below the
setting value. But when the resistance of the filter bag long-time maintains below the setting
differential pressure, the system will automatically strike a new injection when the time interval from
the preceding injection achieves above 420s to avoid the dust long-time sticking on the filter bag.
With the extension of the filter bag service-time, the residual resistance of the filter bag will
gradually increase and the ash removal cycle will gradually reduce. The compressed air pressure for
ash removal will generally maintain after set, but if the ash removal cycle reduces to 10min, it may
enhance the ash removal pressure 0.05MPa, but it should not surpass the highest pressure of
0.45MPa.
Pressure transformer will start the warning if the compressed air pressure for ash removal can
not reach the required pressure after ash removal.
1.8 Equipment’s start-up and shut-down
Please see part three (Operation instruction) for details
ESP+FF combined dust collector is controlled by the program, the program will start or shut the
different goal according to the sending signal, such as, differential pressure, temperature and so on.
The start-up of the ESP+FF combined dust collector is automatically operated by the start-up
program from the PC by the operator.
The ESP electric fields can operate separately, PLC controller will send an instruction to a
group of pulse valves to carry on the ash removal in turn according to the preset ash removal interval
and order when the differential pressure of the FF reaches a setting value. After the ash removal of a
group of pulse valves, the PLC controller will compare the FF resistance with the setting value. If
the FF resistance is lower than the setting value, the ash removal will stop, otherwise, the ash
removal will continue. This kind of control mode can well adapt to the change of the boiler load, it
can maintain the resistance of the dust collector in a proper scope, it is propirious to reduce the
energy consumption of the injection and to prolong the service life of the filter bag.
1.8.1 Start-up
Input the ESP low voltage system and ESP operation, then input the FF program control, when
the program is started up, the outlet damper will open at the same time, The system will
automatically close one bypass damper after four outlet dampers totally arrived, it will close two
bypass dampers after six outlet dampers totally arrived, it will close five bypass dampers after ten
outlet dampers totally arrived, it will close seven bypass dampers after twelve outlet dampers totally
arrived, AB side dampers will act separately at the same time ,the whole preparation work of the FF
start-up is completed after the bypass damper is completely closed, the ash removal way should be
determined and start the corresponding ash removal program by the operator (Differential pressure
ash removal or time ash removal).
If it is discovered that some compartments are not able to give the “REACHED” signal, the
reason should be found out and to be processed immediately.

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 Please see (3.3 Start-up) for step details
1.8.2 Shut-down
The normal shut-down program is handed by the operator.
If the inlet temperature reaches the setting value of heat protection or satisfies the other
protection conditions of the dust collector, the system will automatically carry out the emergency or
protection shut-down program.
Please see (3.4 Shut-down) for shut-down step details

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Maintenance instruction

2.1 Summary
The maintenance of the equipment is carried out by the user guided by the instruction of part 2,
which constitutes the overall guiding documents for the maintenance. Other documents delivered are
mainly to be regarded as supplements to part 2, intended for use in conjunctin with trouble-shooting,
orders for spare parts etc.
All maintenance work should be carried out with the utmost of care in order to prevent personal
injury.
The requirement of ordinary maintenance is mainly depended on the contents of dust and
composition of the gas. The intervals between preventive measures thus vary from case to case.
2.2 Maintenance purpose
The main purpose of the maintenance is to maintain the equipment in good working order and
to minimize the shut-down time as far as possible, in order to meet the best economic operation
requirement of the user.
A condition of the guaranteed performance is that the ordinary maintenance should be carried
out according to the below stipulation.
2.3 Maintenance sequence
The maintenance and inspection of the dust removal equipment should be incorporated in the
systems or programmes laid down for the equipment in general. The intervals for ordinary
maintenance, however, must not be exceeded.
The equipment should be maintained when it shut down for the other reasons.
Record all measures taken and observations made during inspections.
Program operation specified in part three “Operation instruction”should be followed after each
shut-down.
2.4 Requirement of maintenance personnel
For the quickly and efficiently maintenance of the equipment, the maintenance personnel are
required to:
 Have basic knowledge of the electrical engineering, automatic control, hydromechanics
and mechanical engineering.
 Have the knowledge of the design, function and operation of the equipment.
 Acquaint the information of the equipment.
 Understand the safety regulation.
2.5 Ordinary maintenance
2.5.1 Since the need for overhaul depends on operating hours, contents of dust and type of dust, it
may be necessary to change the timer intervals between overhauls based on operating experience.
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Thorough inspections should therefore be carried out during each shut-down for maintenance or
other purposes.
In addition to the normal cleaning of equipment external parts, there is a requirement for a more
thorough cleaning and inspection of equipment components that cannot be carried out while the
equipment is in operation.
Below is a list of continual maintenance with intervals based on experience from earlier
equipments of a similar type.
For maintenance of specific components, please see each “Equipment descriptions” of
equipment.
2.5.2 Inspections for every day
1） Check the differential pressure of dust collector.
2） Monitor the gas flow rate.
3）Monitor the outlet situation of the chimney by eye or continuous monitoring meter.
4） Monitor the ash removal cycle, indicator light or the instruments on the control cabinet.
5）Check the compressed air of pulse cleaning dust collector
6）Monitor the material level of the dust hopper and ash transport system to ensure the normal
transprotation of the fly ash.
7）Patrol the whole dust collector to inspect all kinds of normal or abnormal visible and
audible conditions
2.5.3 Inspections for every week
1）Check all operation parts on the ash transport system.
2） Check the operation of each damper.
3）Check compressed air system, including the lubricate cap and filter on the pipeline.
4）Blow the dust in the side pipeline of the differential pressure meter.
5）Check the operation condition of the temperature transmitter.
6）Add oil on each mechanical drive place which is easily worn.
2.5.4 Inspections for every month
1） Check all pipelines and joints of control gas supply.
2） Check whether the casing of the dust collector is corrosion.
3）Check whether the bypass damper is operating in normal.
4）Check and supply the commonly consumable, such as fuse, indicator light and lubricating oil.
2.5.5 The following inspection should be carried out at least every two month:
Note: Observe safety regulations regarding work in FF.
1）Check nozzle compartments and dust hopper for dust accumulations, clean as required (dust
accumulation in the nozzle compartment indicates damage to fabric bags).
2）Replace or block damaged bags. Follow instructions in the section entitled “Breakdown
maintenance”below.
3）Check access doors and connections for leakage. Replace packings and sealing strips as
required.

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 4）Check the rubber connection under the air tank adjacent to the respective cleaning valve.
Replace the connection if cracks or other damage is found. Re-tighten hose clamps.
2.5.6 Inspections for every three months
1）Check the air tanks for water, oil and corrosion. Open the drain plug and drain any
condensate in the tanks. Then clean as required.
2）Check the cleaning valves, initiate one complete cleaning cycle and check all valves for
proper function.
3）Add lubricating oil for rotating part of the fan when several silicon-controlled parts of HV
control cabinet is cooling.
4） Add oil for speed reducer of rapping and ash discharging.
5） Measure the working condition of the voltage automatic regulator by oscilloscope and make
the records. The working power supply should meet the requirement of the manufacturer; the trigger
pulse is symmetry, plentiful.
6）Clean the filter mesh of the control cabinet.
2.5.7 Inspections for every half year
1）Oil, check and adjust the HV insolator switch and mechanical drive part of safety
mechanical interlock.
2）Rectifier transformer and damping resistance
a. (When high location arrangement) check and clean the accident oil tank and oil
discharging pipeline.
b. Check and replace the respirator’s dryer for the rectifier transformer.
c. Check the oil level for the transformer and add the oil.
2.5.8 Inspections for every year
1）Check the air tanks for leakage.
2）Check the pulse cleaning valves, replace the damaged and worn components.
3）Replace the filter cartridge.

2.6 Breakdown maintenance

2.6.1 Single fabric bags can be blocked with a lid without impairment to the cleaning programme.
When about 10% of the bags in a compartment have been blocked, all damaged bags shall be
replaced.
Fabric bags are delivered in cardboard boxes. Storages should be dry and protected. Boxes must
not be stacked so high that the bags at the bottom become damaged (wrinkled).

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 Injection tube

Spring
Bag cover

Bag plate
Filter bag

Block the damaged bag

Work order for blocking the damaged bag is as below:

1） Clean all dust from the nozzle house when block or replace the damaged filter bag. The dust
acculumated on the bag plate can be absorbed by the cleaner or swept into the dust hopper.
2） Fit the lid over the damaged bag and secure with the spring against the nozzle tube as shown
in the figure 2.
2.6.2 Common breakdown and processing of ESP
Please see original ESP operating manual for details
2.6.2.1 Analyse the breakdown reasons from the operational parameter

/ Pointer indication
Concomitant phenomenon Possible breakdowns
V2 I2 V1 I1
1）Control power of control cabinet is
black out.
2）*1 Automatic regulator of voltage is
The main contactor cannot black out.
close 3）*2 Safety interlock is not in position.
4）General power is black out (Knife
switch has not closed, fuse has exploded
and so on).
Zero Zero Zero Zero
Delayed action *3 Misoperation of LV delay protection
1）Tripping circuit breakdown of
automatic regulator of voltage.
retrip 2）Error output of oil temperature, gas of
Nondelayed
rectifier transformer, overtemperature
protection of silicon-controlled.
4）

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 / Pointer indication
Concomitant phenomenon Possible breakdowns
V2 I2 V1 I1
Tripped after operation for a
Trigger pulse outlet and breakdown of
period. Non-output before
phase shifting link, triggerless pulse outlet.
trip (or switch on again).
After switching on,
Explode quickly.
conduction angle is 100%
It will trip as soon as the main
Breakdown of silicon-controlled
contactor switched on, along
part (punctured), correct action of
with intense current surge, air
over current protection.
switch may also trip.
Loop breakdown of secondary
Other instruments
Trip voltage measurement (wire break,
have swinging display
parallel varistor is punctured and so on).
Zero Normal Normal Normal except V2 (or swing
Instrument breakdown (the meter is bad,
after arise the current Not
cables are disconnect, the indicator is
limit). trip
jammed etc).
No flashover, commonly *5 Electric field & HV power supply
trip loop is short.
Along with the temperature
rising of flue gas, the flashover *6 CE plate heat expansion causes the short
in the electric field aggravates to of the electric field.
zero or arc discharge of V2.

The electric field is short, LV delay

Zero Big Normal Big Delayed
protection is correctly acting.

When nondelayed,
Trip I1 、 I2 exceeds the
rated value,
*7 Current limit is out of control.
possibly along with
explode and fast
melt.
1）Reducing phenomenon of electric
Along with LV trip
field different electrodes distance is very
of arc discharge
Frequent serious.
Low Small Low Small phenomenon
flashover 2）*8Electric field exist incomplete short factors.
Commonly does 1）Depositions on the electrodes are serious.
not trip 2）Deviation of different electrode distance is
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 / Pointer indication
Concomitant phenomenon Possible breakdowns
V2 I2 V1 I1
serious.
3）Automatic regulator of voltage is false shining
(the flashover sensitivity is too high,
antijamming ability is bad, the measure is
incomplete).
4）*9 The working condition is not suitable.
1）*10 Breakdown of current limit section
No flashover or the setting is not suitable.
2）There is question on phase shifting control.
Rectifier transformer has
unusual voice, temperature
arising is excessively high, *11 Leaning excitation of rectifier
Lower Smaller Lower Big
instruction of silicon-controlled transformer is serious.
conduction angle is very
possible, the fase fuse runs hot.
Rising of the primary, secondary HV side of rectifier transformer is short. For
current differs so example: rectifier bridge is short; equalizing
much,
Low Small Low Big possibly has the current surge, electric capacity is punctured; interturn ofHV
temperature of rectifier package is short and burnt out.
transformer rises up.
Rising of the primary, secondary
current differs so much and
1）、Short breakdown of rectifier transformer LV
primary current will increase
package.
Very and change suddenly, the fuse
Low Small Low 2）、The insulation of rectifier transformer core
big may explode, the switch will
(including the core-through bolt) is damaged, the
trips, temperature of transformer
backset is serious.
rises abnormal and the abnormal
sound is obvious.
1）、The deposition on the electric electrode is
serious and the specific resistivity of the ash is
low.
2）、Deviation of electrode distance installation is big.
Normal Big Flashover
Low Big 3）、Welding of the casing is not good, airproof of the
access door is bad, which cause the cold gas to impact
the DE, CE part and make it condensation, distort, and
the distance of the different electrodes becomes small.

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 / Pointer indication
Concomitant phenomenon Possible breakdowns
V2 I2 V1 I1
1）、Back corona phenomenon.
Frequent flashover
2）、Shaking of electrode plate, electrode wire.

1）、Electric field assumes low resistance (for

example, the partial ash bridging).
Flashover occasionally, 2）、Creepage of HV insulation part (such as,
sometimes V2 will lower porcelain shell, shaft insulator, wall bushing)
when I2 is bigger. after the insulation dropped.
3 ）、 HV cables and terminals discharge to
ground. (Low position arrangement)

1）、 Dust concentration is low, electric field

approaches to no-load.
2 ）、 HV cables and terminals are seriously
leaking. (Low position arrangement)
3）、HV part may grounded by other things.
Big 4）、High specific resistivity dust or flue gas
Low Big Normal No flashover
character change corona and voltage.
5）、HV sample in the control cabinet loops,
discharge tube is soft punctured.
6）、The discharge tube in parallel with HV sample
resistance in the rectifier transformer is soft punctured.
1）、Lower part of DE wire is dropped or broken.
2）、Electric field will transit to short circuit or
Irregularly flashover, needle
chan incomplete short circuit condition due to the
change change change swings fiercely sometimes.
ge factor that hopper is full and so on.
3）、Change of working condition is big.
1）、DE wire is dropped or seriously distorted.
2）、Central dislocation of frame and terminal
causes massive wires are not in the central
Norm
Smaller Normal Smaller No-load current is small. location of evenly discharging.
al
3 ）、 The equipment is old, wire terminal is
serious deactivation.
The difference between
Inco
Normal utilization factor and 0.64 - *12（Wrongly instruction of secondary voltage
rrect Normal Normal
0.70 is far.
1）、Deposition on electrode plate and wire is

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 / Pointer indication
Concomitant phenomenon Possible breakdowns
V2 I2 V1 I1
Norm Small Normal Small Frequent flashover serious.
al 2）、Initial phenomenon of back corona appears
due to the dust resistivity is excessively high.
3）、Dust concentration is excessively high, cause
corona block.
4）、Earthing resistance is excessively high, HV
loop is not good.
5）、HV output is bad contact with electric field.
Operations of
other electric field
start-up,shut-down *13 The antijamming ability of the device is bad,
or trip the measures are not perfect.
Thunder and
lightning influence
Easy to trip in the *14 Part has the thermal breakdown or the
Sudden summer characteristic change
trip Secondary current 1）、*15 Misoperation of overcurrent protection
increases when the 2）、Misoperation of overtemperature protection
working condition of the rectifier transformer and
changed silicon-controlled.
Secondary voltage *16 Misoperation of overvoltage protection
Norm increases when the
Normal Normal
al Normal working condition
changed
1）、Gas distribution is uneven.
2）、Second floating is serious.
3）、Air leakage of electric fields (for example,
the baffle plate of hopper is dropped, the flue is
bypassing) is serious.
4）、The distance tolerance between different
Collection efficiency is low
electrodes is excessively big.
5）、Air leakage rate is very big, which makes the
flue veloctiy increasing, temperature dropping,
thus weakening the particle discharge
performance.
6）、Particle resistivity is excessively high, even
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 / Pointer indication
Concomitant phenomenon Possible breakdowns
V2 I2 V1 I1
come into back corona cause the drive polarity
dropping, and the deposition on the electrodes
makes discharging slowly, big adhesion causes
the hard rapping dropping.
7 ）、 Design of controls parameter is not
reasonable.
8）、The flue condition entering into the ESP not
meets the original design condition, the working
condition changed.
9）、The equipment has the mechanical breakdown, for
example, the rapping function is not good, etc.
HV loop is complete opening (The damping
resistance burns out, the position of isolator
No flashover
switch is not right).
Flashover and secondary HV loop is incomplete opening (Dampling
Very
High Zero High current suddenly arise from resistance flashover, connection wire is bad
small
zero to normal value, contacted, the position of isolator switch is not
changes repeatly, voltage right, working earthing wire is bad contacted or
value hastens high. broken).
Critical coronal voltage is high, Deposition on the DE wire is serious, dust
secondary current is smaller. resistivity is high.
Critical coronal voltage is high,
secondary current is obviously
Deposition on the electrode wire, plate is serious
High Small Normal Small small, and electric field voltage
and the distribution is not even, dust resistivity is
will achieve the standard value
high.
by raising the voltage of single
power supply.
Note: massive “*” marks in “Analyse the breakdown reasons from the operational parameter” is to furtherly
analyse and explain the breakdown reasons.
*1 Automatic regulator of voltage is black out.
There are many kinds of factors, more common is that the insert connection of the adjustor is loosen,
which causes the bad contact, also there is a kind of power supply set, the mastor contactor has a pair
of auxiliary and normally open contact which enter into working power supply loop of the automatic
regulator of voltage, because the actually on/off voltage of this contact is 23V, and due to the
environmental factor, it is easy to cause bad contact and black out of the regulator. Another
possibility is that the glass tube fuse of the equipment is bad contacted or broken.
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*2 Safety interlock is not in position.
According to the characteristic of the ESP, it should have safety interlock set as soon as open the
access door, considering the reliable operation of the sytem, mechanical and electrical synthesis
interlock will be adopted at here generally, that is there is only one lock on the spot, it can be opened
only by the key which is inserted in the interlock panel, one key for one lock, when take down the
key, control power supply of the corresponding one or several electric fields will be shut off,
sometimes the key may be forgotten to be returned or in position after overhauling. Usually HV
isolator is not allowed to open operating, here is loaded with limit switch and use electrical block
system, the situation is not rare in actual that control loop is impassable due to the limit switch is not
in position.
*3 Misoperation of LV delay protection
The design of LV delay protection is based on this mentality: when the electric field is completely
short, although it will not damage the equipment at once, but it will waste the electrical energy, the
operation is meaningless, when the electric field appears arc discharge frequently, this situation is
harmful to electric field equipments and power supply set, the electric field should be stopped. When
the electric field appears arc discharge frequently, on the one hand, the electric field approaches short
condition, on the other hand, prompt response of automatic regulator of voltage causes the
silicon-controlled to be blocked for a period of time, therefore the signal reflects that the electric
field is at the low voltage condition at a certain time, the frequently arc discharge can be ensured and
the trip can be protected by setting a reasonable delay time and LV setting value. Generally the LV
value is set at the critical coronal voltage value or a slight higher value, because the operation lower
than the critical coronal voltage is meaningless to the ESP. LV delay protection must avoid this
situation, which is when the main contact is closed, due to various reasons, electric field voltage has
not risen to the setting value above when arrived the delay time, LV delay protection should not act
at this situation, the conventional block system is to establish a monostable circuit, this monostable
circuit will turns over only when there is primary flashover or arc discharge or the secondary current
arrives the setting value during the start-up procedure, this will relieve the block system for the LV
delay trip link. Sometimes misoperation of LV delay protection may occurs in the start-up due to this
block system link is breakdown. One kind of situation is easy to take for misoperation, that is there is
incomplete short factor in the electric field, flashover presents when the secondary voltage is still
very low (average value of secondary current is still very low at this time, even the instrument does
not show), observe attentively at this time, judge the flashover is false phenomenon or there is spark
or flashover in the electric field by observing feedback current waveform through the oscilloscope
(waveform of secondary current appears the peak at this time), if the parameter is normal and
electric field appears LV delay trip, it’s possible that the trip is improper set or the setting value is
changed and not suitable for the existing condition, it should be properly adjusted by adopting
measures, such as, increase the delay time, arise the +du/dt of LV stage or reduce LV setting value.
*4 In the misoperation of rectifier transformer, silicon-controlled part excess temperature
protection, characteristic change of temperature element is a big factor. When rectifier transformer is

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in high position arrangement, protection contact is short circuit due to the rain may cause the excess
temperature. Situation of gas protection misoperation also occurs.
*5 Electric field & HV power supply loop is short.
There are many reasons cause the completely short of electric field, arrange it according to the
probability of occurrence, is that: full ashes in dust hopper, fallened and broken electric wires join on
the CE plate, clip of CE board is disconnect, temporarily earthing wire used in overhauling has not
removed, metallicity sundries (such as welding rods) are left on the bridge between the DE and CE
when overhauling, HV cables and terminals are completely punctured (Low position arrangement),
electric fields has not good maintained after long stoppage or electric field has not prompt dried after
water flushing and cause the melt rust corrosion and big pieces of rust are stripped to the DE and CE,
insulation parts are completely punctured (in the majority situations, insulation parts are punctured
under LV and along with flashover, the situation that completely punctured and zero voltage is few).
*6 CE plate heat expansion causes the short of the electric field.
The flue gas temperature arises too much due to the entire production technical appears abnormal
condition, then the impeded thermal expansion will cause the serious reducing of the diffenent
electrodes distance of electric fields, cause the dropping of the parameter until short or arc discharge.
In the actual, it is discovered that there is also impeded thermal expansion after operation for a
period of time in the same fule gas temperature, it is may related with the extension, distortion, the
stress realease, partial loosen and abrasion etc of the structure, it is worth further analyzing, it
increases the difficulty for the impeded thermal expansion distinction.
Expansion clearance is the distance from the bottom of the electrode plate to distribution mouth of
the hopper baffle at normal temperatures, because the designs, unreasonable installation or the
operation condition has seriously deviated and surpass the normal range etc, the thermal tensile lenth
of the electrode plate surpasses the expansion clearance, it will cause the electrode plate to be bent,
its order of severity can be simple calculated, L1 is the length of the electrode plates under normal
temperatures, L2 is the length of the electrode plates under working conditions, after bending, it
should be curve, due to the α angle is very small, it should be instead by straight line, d is the
bending distance at the horizontal direction (that is the shortened distance of different electrodes
distance).
Set S= L2 - L1， then the practical significance of S is insufficient part of expansion allowance,
because L1＞＞S, then

2
d SL1 „„„„„„„„„„„„„„„„„„„„„„„„„„（10-1）
2
If L1=1200mm，S=1mm，then d=35mm. The conclusion is: so long as the electrode plate slightly
collided with the hopper baffle, the electrode plate will be seriously bent, the different electrodes
distance will be big shortened (the simple estimate has not considerated the rigidity of the electrode
plate and hopper baffle). Judge the completely short breakdown or imcompletely short breakdown
due to impeded thermal expansion, different V-I characteristic curves are its chief feature when the
temperature is different, for example, the cold voltage rising is normal, secondary voltage drops or is
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FEIDA ENVIRO
zero under thermal condition, secondary voltage drops gradually when the flue gas temperature is
rising, sometimes the parameters will be recovery by opening the corresponding access door
(sub-cooling function, usually this experiment can not be done). Sometimes it can be judged from
some subtle points. After bending of the electrode plates, many different electrodes distances are
shortened, then secondary current will be bigger under the same voltage, and the degree is related
with quantity of electrode plate which are impeded thermal expansion, for example, the flue gas
temperature of the electric field is high, generally it will has impeded thermal expansion, when the
same operation voltage is 35KV, the current will arises from the common 0.1～0.2A to 0.4A. When
stop the boiler for overhauling, the impressions always can be discovered on the hopper baffle,
baffles also can be bent, actual expansion quantity of the electrode plates under the working
conditions can be measured from the marks on the location plate which is left by the unbent
electrode plates.
*7 Current limit is out of control.
Incontrollable breakdown of “Current limit” has the invisibility, it can always be discovered in
actual, when the electric field is short, if “Current limit is out of control”, primary and secondary
current will surpasses the rated value, and overcurrent protection of the primary current will act in
the normal condition.
*8 Electric field exist incomplete short factors.
Incomplete short factors can be devided into kinds: one kind is that insulation of HV insulation
part drops; one kind is that there is other things in the electric field, such as, dropped small pieces of
rust and ash mixture etc; another kind is that there is a few of ashes on the bridge which is between
the DE and CE, it will appears different short characterisitic according to the quantity and resistivity
of the ash, for example, sometimes it will transit to complete puncture under very low voltage,
sometimes it will cause the dropping of the voltage, sometimes it will keep the resistance value in
the quite big voltage range, so only the secondary current increases on the pointer indication.
*9 The working condition is not suitable.
This is a comprehensive factor, for example, removal performance of the coal and ash dust is
very bad, specific resistivity of the dust is very high, or specific resistivity of the dust is not very
high but its stickness is very big and cause the serious deposition of the electrode etc.
*10 Breakdown of current limit section or the setting is not suitable.
What is called the not suitable setting is that some potentiometer settings are not suitable of
which the function is limit the current in the automatic regulator of voltage, at this point no matter
operators how to adjust the “Current limit” on the regulation panel, output will not increase, this is
because that secondary current output limit in the regulator is set too small, the correct setting is that
when the “Current limit value” on the panel is set to the maximum value (i.e. 100%), the internal
current limit will just limit the secondary current in the rated value.
*11 Leaning excitation of rectifier transformer is serious.
Power supply unit occurs leaning excitation is that when 380V alternating current is input
rectifier transformer after controlled by the silicon-controlled, the top and bottom primary voltage

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waveform is not symmetrical, for mild leaning excitation situation, the other parameters will not
obviously change except the primary current will slightly increase; for serious leaning excitation
situation, the voltage waveform which is input to the rectifier transformer after silicon-controlled
parts only has positive half wave and negative half wave, this kind of voltage is equal to cocurrent
pulsating voltage, due to the internal magnetic field of transformer is high distortion at this time,
there is abnormal vibration and sound in the rectifier transformer, transformer temperature will
obviously arise due to the increasing of iron and copper loss, because the secondary voltage always
can not achieve electric field breakdown voltage, silicon-controlled conduction angle can achieve
100% indication at this time. The main reason of mild leaning excitation is that two groups of circuit
parameters have changed which produce sequences to trigger pulse, it can only be discovered by the
oscilloscope at this time; and the serious leaning excitation is that a group of pulses have output loop
breakdown or a silicon-controlled is breakdown (opening). After the leaning excitation occurs,
because the primary current has many direct components in it, its actual value is bigger than the
pointer indication value which is transformed after through the current transformer, and it also
affects the correct action of primary overcurrent protection, it is especially importance when
analysising and judging the harm of leaning excitation.
*12 Wrongly instruction of secondary voltage
Except the meter is broken, for example, the indicator is jammed, the bearing is excessively
worn, the meter is disconnected. It is discovered that wrongly instruction of secondary voltage has
the very big relations with HV sample loop, for example, the loop measurement is bad contacted
(including compensating loop of instrument indication); HV sample resistance of rectifier
transformer is incorrect; in some equipments, some resistances of the HV sample series resistance
are burnt out; in some equipments, when the control feedback voltage and indication voltage are got
from the same point, the change of feedback quantity will cause the deviation of the indication value
etc, in such situation, the voltage meter will have big deviation in the normal maintenance and
overhauling even if it has been examined by the standard meter while erecting, because normally
only the pointer indication is examined in the overhauling, if want to arise the accuracy rate of the
secondary voltage, the standard level of sample signal and the reliability of the components should
be enhanced. Sometimes, it can be judged by utilization factor, its principle is: Utilization factor
K=η·Cosφ „„„„„„„„„„„„„„„„„„„„„„„„„„„（10-2）
η is the efficiency of the ESP power supply unit, Cosφ is its power factor, then
V2I2=KV1I1 „„„„„„„„„„„„„„„„„„„„„„„„„„„„„（10-3）
It is stipulated in the related ESP power supply standard, at the rated parameter, K≥0.64, in
actual, it is around about 0.64～0.7. In actual, error indication of V1、I1、I2 is small, suppose its
indication is accurate, then the actual value of V2 can be inferred approximately by using the formula
10-3, of course this kind of estimate is quite rough, it is just suitable for the situation that the
indication value V2 is seriously deviated with the actual value.
*13 The antijamming ability of the device is bad, the measures are not perfect.
This is a comprehensive problem, it involves the antijammping ability of the automatic device,

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it also involves the working condition and external connetion condition of the electric control device,
in the ESP devices, it is stressed that the secondary voltage and current signal feedback must use the
qualified shielding wire, and one end of the shielding layer should be good earthed. Earthing
resistance of the ESP casing and the earthing of the HV control cabinet meet the design requirements.
The antijamming ability of the device, besides the quality assurance of the components, it also
involves the line trend, signal isolation, the design of antijamming loop etc. Please refer to the
relevant content of GB/T 3797-2005 <Electrical control device> for details.
*14 Part has the thermal breakdown or the characteristic change.
It will change each kind of control signal of the device, makes the logical relation confusion,
easily cause the frequently trip, because this kind of breakdowns are closely related with heating
components after operation for a period of time, when shut-down and overhauling, the breakdown
characterisitic is not obvious, the breakdown is difficult to find, but the reasons of this kind of
breakdowns have the certain regularity, for example, the components have not been good aging
screened, environmental temperature of the control room is too high and not suitable for the normal
operation of the device, the device has been used for a long time and has presented aging sign etc.
*15 Misoperation of overcurrent and overvoltage protection
It always appears when the secondary current is bigger or secondary voltage is higher due to the
working condition changed, there’re several aspects for its reason, one aspect, overcurrent and
overvoltage protection link in the present device can not be designed such accurate and reliable as
the relay protection device; another aspect, if the stability of device is not very high, its setting value
can be easily changed due to the change of potentiometer resistance value (it is always caused by
increasing contact of contactor and resistance), capacitance value, transistor’s characteristic in the
link; the another aspect, if the environmental condition is too bad, for example, invasion of dust,
humidity is equal to attach a loop on the electronic circuit, temperature is too high and change the
characterisitic of the semiconductor, can also cause the misoperation.
2.7 Filter bag replacement
Shut down the relevant compartment to replace the filter bags in accordance with the instruction
for blocking above. Of course, it is also possible to replace the filter bags with the entire equipment
shut down.

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See below pictures for filter bag replacement

Proceed as follows:
1） Loosen the nozzle tube of the row of bags to be replaced by pulling the pin at the rear edge of the
tube.
2） Turn the pin and remove the nozzle tube.
3） Pull up the wire cage to the joint.
4） Secure the lower part onto the frame with a pin. Loosen the locking ring and remove the upper
part of the cage. Pull up the lower part. Check the wire cage for damage. Replace as required.
5～6）Take hold of the fabric bag and pull it up. (The bags can also be dropped and then removed
through the access door of the dust hopper.)
7～8）Fit a new fabric bag. Snap it onto the frame.
9）Carefully introduce the lower part of the wire cage and secure it onto the frame with a pin. Fit the
upper part and secure it with the locking ring.
10) Remove the pin and introduce the upper part. The wire cage is tapered and becomes fixed onto
the frame. Repeat items 3-11 with all damaged bags in the row.
12） Re-install the nozzle tube.
13） Secure the tube with the pin.
Repeat item 1-13 with all rows of damaged bags.
Besides the recording of regular inspection result, the operator should record all maintenance
works for FF, especially the replacement of filter bag. When replace the filter bag, the record chart of

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filter bag replacement should be filled in. This can record the damage tend of the filter bag, which is
helpful to find out the reason of damaged filter bag.

Record chart of filter bag replacement (mark “╳”on the damaged filter bag)

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Project name: Equipment name: Replace time:
Nozzle house No. :(Back to inlet duct of FF)left side/right side, Air tank

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18

22 ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○
21 ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○
20 ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○
19 ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○
18 ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○
17 ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○
16 ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○
15 ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○
14 ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○
13 ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○
12 ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○
11 ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○
10 ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○
9 ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○
8 ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○
7 ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○
6 ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○
5 ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○
4 ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○
3 ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○
2 ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○
1 ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○

Breakage position and characteristic description:

Analysis the breakage reason:

The common and usual problem of pulse injection FF is that there is water and oil content in
the compressed air which is used for ash discharge. During the ash discharge, the water and oil

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which are blowed into the filter bag will permeate the filter material, wetting the dust and then block
up the filter bag. The result is that the pressure drop increases and have to replace the filter bag of
which the filter hole is blocked up. The oil content is generally from the leakage of compressor
piston ring and seal components, and water content is from the air. Air dryer of the compressed air
system must work normally, and the air filter on the compressed air pipeline should be inspected
according to the scheduled time.
Table 2 lists the breakdown analysis and elimination method for generally instruction.

Table 2: Guide of breakdown maintenance

Breakdown
Possible reason
appearance
The function of ash discharging system
of the filter bag is abnormal.
The ash discharge is inefficiency.
There is acid condensation on filter bag.
Measures
Check all parts of the ash discharge system
 Adjust the injection pressure
 Check the permeability of filter bag.
 Check the compressed air is clean or not.
 Don’t let oil gas pass the filter bag.
 Raise the temperature of flue gas
 Reduce the air leakage.

 Confirm the quantity of flue gas.

The filtering velocity surpasses the
 Reduce the inlet quantity of flue gas when
The resistance design value.
possible.
is too high.
There is a big change of inlet dust  Test the concentration and particle size of
concentration and particle size flue gas.
distribution  Check the change of process engineering.
 Blow the pipeline by reverse air
 Protect the measuring point, make sure that
Testing pipeline of differential pressure
there is no deposition on it.
is jammed.
 Add blow wash system on the measuring
tube.
Breakdown of differential pressure  Examine the differential pressure by other
meter differential pressure meter.
 Blow the pipeline by reverse air.
 Protect the measuring point; make sure that
The resistance Measuring tube is jammed. there is no deposition on it.
is abnormally  Add blow wash system on the measuring
low. tube.
Measuring tube is broken or
unconnected

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 The ash discharge of filter bag is Reduce the injection pressure and/or prolong the ash
excessive. discharge cycle

The filter bag is broken. Replace the filter bag

High emission Bypass damper is leakage. Check the airproof of the bypass damper.
concentration
There is leakage between the inlet &
Check and maintain.
outlet flue duct.

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Operation instruction

3.1 Summary
Measures to be taken before start-up of the plant are specified in the section”Measures before
start-up”. These measures, as well as other measures specified in these instructions, should be carried
out in the order specified.
 The start-up process is described in the section “Start-up”.
 The heading “Inspections and measures during operation” refers to inspections and
measures, which are to be carried out periodically when the plant is in operation.
 The shut-down process is described in the section “Shut-down”.
 The section “Special measures” describes the processes for pre-coating of the filter bags。
 Measures to be taken when alarms are activated are specified in the section “Breakdown
alarm”.
3.2 Measures before start-up
The below measures are to prevent injury to personnel and damage to the equipment.
Before start-up, ensure:
1）That no repairs or maintenance work are in progress, and that all access doors are closed, all gas
circuits are open.
2）That the compressed air system is turned on and meets the requirements specified.
3）That the pressure of the compressed air cleaning system is correctly set.
4）That all predetermined values are set correctly.
5）That dust hopper can receive dust (check the level)
6）All locally control boxes have been switched to “Remote” position.And All console switch of
damper must been switched to “open” position.
7）Trial operation of the bypass damper is normal, all bypass dampers are swtiched to “Auto”
location from the PC, the bypass damper will automatically open(check on the display)， the bypass
damper is in open position after normal shut-down.
8）The operations of outlet damper are normal, trial operations should be taken before each
start-up. After that, switch the inlet baffle and outlet damper to the position of “Auto”from the PC, at
this time outlet damper automatically in the closed position (check on the display).
9）Put into the dust hopper heating 24 hours before fire the boiler.
10) Deliver the hot wind and insulator heating system 6-12 hours before the electric field put into
operation, to avoid the creepage due to the condensation of the insulator parts.
11）Each ash discharge rapping should be put into operation and start the corresponding ash
transport system immediately after firing the boiler.
12）All locally reducing valves are correctly set. Control box of damper valve is set above 0.5Mpa.
The forerunner gas pressure of air tank solenoid valve is set about 0.30Mpa, it is normally 0.05Mpa
higher than pressure of the pulse injection. Pressure reducing valve of pulse injection is set about

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FEIDA ENVIRO
0.25Mpa.
13）Check the electric filed: clean the electric field, and to ensure thers is no body in it, strictly
seal the access door.
14）The auxiliary electric equipment of the ESP should be carried on the routine inspection.
15）Inspect the auxiliary mechanical equipment of the ESP.
16）Inspect the HV power supply unit of the ESP.

3.3 Start-up
3.3.1 Summary
Verify that all measures before start-up have been taken before start the boiler and ID-fan
FF is operated by the PC, and interlock protected with the related signals. The bypass damper
and temperature, differential pressure and outlet damper are interlocked. To relieve the related
interlock, it need to enter into the parameter picture or the operation picture of damper, the bypass
damper will not have the interlock protection with this signal after relived the interlock. (Note: This
function is generally used in the adjusting and overhauling).

Click the above corresponding button to choose the content which needs to be shielded. The red
means the interlock is input, the green means the interlock has been relieved.
3.3.2 Start-up step
3.3.2.1
Basic step of ESP electric field start-up is as below：
A、 Close the air switch of HV control silicon; check the change-over switch at the “Manual falling”
position, then release the control source.
B、 Select the proper control method, voltage rate of rise and decline according to the working
condition.
C、 Adjust the limit value of the current to the minor position.
D、 Press the start-up button, turn the change-over switch to the “Manual rising” position; observe
the rising process of the electric field voltage and current, after that, turn the change-over switch
to the “Automatic” position, and develop the “Current limit” gradually.
E、 Start up the cooling fan of silicon-controlled when the ambient temperature is higher than 25℃
or the silicon-controlled part gives out heat seriously.
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F、 Inspect the high and low voltage of the dust collector after operation.
3.3.2.2 External conditions of FF start-up
The below instructions should be followed to maximize the filter bag life. The procedures imply
that the amount of moist, acidic and sticky dust collected on the filter bags during the start-up phase
is minimized. The dust cake left on the filter bags (dust cake from pre-coating of fly ash left on the
bags when the filter bag was taken out of operation) additionally protects the filter bags.
1） Verify that all measures before start-up have been taken.
2） Start the ID-fan.
3） Start the boiler.
4） Start the ash discharge system.
5） Start the FF operation sequences when below conditions are fulfilled:
— The combustion of the fuel shall be proper (indicated by e.g. a CO content of less than
250ppm).
— The flue gas temperature ought to be at least 20℃ above the acid dew point.
— The FF shall not be connected to the flue gas stream until coal starts to be fired in the boiler
and the thermal power achieves 80% above the total thermal power.
6） In case the FF was connected to the flue gas stream prior the flue gas temperature was 20℃
above the acid dew point, measures shall be taken to rapidly raise the flue gas temperature to the
recommended level.
3.3.2.3 PC operation of FF start-up
Operation of the plant is supervised by PC. Sequences and separate objects are started from the
relevant display in the order specified below:
1）Enter into the main picture of monitoring.

2）Enter the system and obtain the corresponding operation permission

The person must have the administrator’s operation right, or he can not modify the
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 parameter or operate some important function button. And to be an administrator, you must
login the below picture or quit first.

3）The flue gas can only be cut into the FF after the temperature arrived 120℃, click the “FF
Operating”button on the main monitoring picture, it will pop-up the below picture, click the“Run”
button under the Damper Control, the equipment will automatically open the outlet damper, close the
bypass damper, the start-up process will finished after all damper signals have arrived.

5）Ascertain the injection mode (Time control/DP control). Click the “Open” button in the
operation button menu to start the jetting.
3.4 Inspection during the operation
This section specifies the inspections, which are to be carried out each day on a regular basis
while the plant is in operation.
Under certain conditions regular inspection rounds out in the plant are required in order that
breakdown shall be detected at an early stage and corrective measures be taken.
In order that information of the operation shall be disseminated to those concerned, a log book
shall be available, in which appropriate entries shall be made, e.g. date and time of shift changes,
operator changes as well as information on changes in operating conditions and the occurrence of
breakdowns or alarms activated. Statements on inspection rounds carried out and measures taken
shall also be entered.
3.4.1 Operation conditions
Below conditions must be fulfilled during continuous operation when the FF is connected to the
flue gas stream.
The amount of oil fired is limited to maximum 20% of the produced thermal power. The
remaining minimum 80% shall origin from coal firing.
The combustion of the fuel shall be proper (indicated by e.g. CO content of less than 250ppm).
The flue gas temperature shall be at least 20℃ above the acid dew point.
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 3.4.2 Inspection in the control room of PC
1） Verify that all operating values shown on the display are normal.
2） Verify that no alarms have been activated. Measures to ba taken are specified in the section
“Breakdown alarm”
3） Verify that outlet flue-gas temperature of the boiler is normal. If not, check the boiler for
proper operation and take associated measures.
4) The outlet emission should be examined, if it is too high, then need to examine the seal fan
or bypass damper, or stop the boiler to check the filter bag is broken or not.
NOTE! When about 10% of the bags in a compartment have been blocked, all bags shall
be replaced.
3.4.3 Inspections on each part of the system
Current safety regulations must always be observed.
1）Check all lines carrying air, fly ash or flue gases for leakage.
2）Check all machines for abnormal noise.
3） Check the equipment for dust leakage. Stop any leak discovered without delay and clean as
required.
3.4. FF
1）Check all cylinders (dampers) for leakage.
2）Check all pressure vessels for abnormal pressure.
3）Verify that the frequency of cleaning pulses is normal

3.4.5 Patrol inspection of ESP

Device Part Key and request of inspection Inspect time
1、Operation condition of silicon-controlled heating and Once/shift
cooling fan
HV control 2、Heating condition of major loop (Mainly cable head) Once/shift
cabinet 3、Commenting condition of flashover and arc discharge Once/shift
4、Ash accumulation condition in the cabinet (Mainly the Once/shift
HV voltage automatic control)
Power 1、Voice, oil temperature, level, color of transformer Once/shift
Unit 2、Heating condition of inlet cable head Once/shift
Rectifier
3、Oil leakage of transformer Once/shift
transformer
4、Dryer color of respirator Once/shift
(Reactor may
5、Damping resistance and junction is overheated, Once/shift
refer to a part)
flashover,opening or not
6、HV insulation part is flashover or not Once/shift
1、Position indication and arriving situation of HV switch Once/shift
2、The mechanical block system of isolating switch is good or Once/shift
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HV HV switch not.
Power cabinet 3、HV cable and introducing place is discharging or not, oil Once/shift
Unit immersed cable is leakage or not
4、Insulation part is discharging or not Once/shift

1、Condition of oil temperature, level, color and leakage Once/week

Power 2、Condition of voice, cable head heating, operation Once/week
transformer 3、Damping condition of the dryer of respirator Once/week
1、Heating condition of busbar and each special-purpose plate Once/week
Power connection place
distribution 2、Heating condition of each cable and junction, shutting and Once/week
device & cable plugging condition of cable hole
LV interlayer
Control Assistant device 1、Rapping program-controller is deviation, error or not. Once/week
Device (Ash discharge,2、The self-control of ash discharge and electric heating meets Once/week
& rapping, electric the request or not.
Power heating etc), 3、Internal wiring of each power box is loosened or not, the Once/week
Unit Electric control fuse is burned or not, thermal relay and air switch is acting
device, thermal or not.
control 4、Sampling head of CO analyzer and suction pump, Once/week
instruments flowmeter, pointer indication of the instrument are normal
(Constant or not.
temperature, 5、All kinds of equipments, such as, control panel, protection Once/week
patrol measuring, panel, instrumentation are clean or not, the wiring is
CO analyzer etc.) loosened or not.
1、Insurance is broken or not Once/shift
2、The speed reducer is leakage or not, it is rapping or not, it Once/shift
Rapping device
is superheating or not, there is abnormal voice or not.
Casing 3、Operation of motor is normal or not. Once/shift
equipmen 1、Each access door is tight or not. Once/week
t 2、Whether the casing exist the greator leakage (There is Once/month
The whole sound under negative pressure and flue under positive
pressure).
3、Insulation and protection plate is dropped or not. Once/month
1、The pressure of ash ejector is normal or not, injection is Once/2 hours
Ash clogged or not, the ash ejector slot is clogged or not, water
Ash discharge
discharg tank of ash ejector is smoking or not, the ash tube is
system
e system smooth or not.
2、Pressure of pneumatic ash discharge is normal or not, the Once/2 hours
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 tube is smooth, smoking or not.
3 Ash discharge motor is in normal operation or not, the place, Twice/shift
such as, sluice valve is smoking or not, the speed reducer is
normal or not.
1、The dust hopper is clogged or not Twice/shift
2、The electric heating is normal or not, there is cold dust Twice/shift
Dust hopper
hopper or not, or the heating steam tube is leakage or not.

3.5 Shut-down
3.5.1 Shut-down of ESP electric fields as follows:
A. Turn the transform switch to “Manual falling” position, low voltage delay tripping of
power unit will automatically perform and can also be manual switched out after the
voltage and current of electric field steady dropped to a certain value.
B. Cut off power supply of the control, turn the air switch of HV control cabinet to
“Detaching” position.
C. If the equipment is in maintenance condition, turn off the knife switch of power supply,
hang the warning board.
D. Change the position of HV isolating switch to the position of overhauling (“Electric
field-Earthing” or “Electric field, power supply-Earthing”).
If operate on the PC, then directly stop the operation of the HV control cabinet on the PC.
（1） Stop the operation of the ESP equipment promptly:
① Electrical aspect
A、When the rectifier transformer and reactor give out heat seriously, the temperature rising of
the reactor is > 65℃, the temperature rising of the rectifier transformer is >40℃ or there is
obvious flashover, arc discharge, vibration and so on in the internal of the equipment.
B、 Damping resistance breaks out fire.
C、 The flashover of the HV infrared ray part is serious, the HV cable head breaks out flashover
and discharge.
D、The power unit is out of control, present the big current surge.
E、 Electrical equipments break out fire.
F、Other conditions seriously threaten the safety of the personnel and equipment.
② Mechanical aspect
A、Electric field breaks out short circuit.
B、 The distance of interior electrodes reduces seriously, the electric field breaks out arc
discharge continuously.
C、 CO concentration has been to trip value (Generally 2%), or the sign indicates that there is a
spontaneous combustion in the electric field.
D、Stop the motor promptly if the rapping, ash-discharge mechanism has been jammed; stop
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 the operation of ash discharge valve if the water breaks off when adopting water-type ash
discharge.
（2） Stop the operation of the ESP equipment according to the circumstances:
① Electrical aspect
A、 Rectifier transformer and reactor give out heat seriously and have surpassed the normal
allowance.
B、 Damping resistance breaks out fire, power unit presents the leaning excitation.
C、The cooling fan of silicon-controlled part is breakdown and gives out heat seriously
D、All kinds of cable heads, especially the cable head of major loop, the rectifier transformer,
the inlet joint of the reactor give out heat seriously.
E、 The HV insulation can not meet the demands when starting up.
② Mechanical aspect
A、The dust hopper breaks out ash clogging.
B、Throw the oil into the boiler.
3.5.2 FF shut-down can be devided into normal shut-down, emergency shut-down and automatic
shut-down.
Normal shut-down is completed by the operator on the PC; Emergency shut-down is completed
by the program automatically by judging the external conditions (such as the alarm and stop of boiler,
ID fan).
(1)Normal shut-down
When normal shut-down, press the operation button of “Close” as the below picture; after the
stop of pulse injection, press the button of “Stop”as the below picture after a certain time (Generally
considering above 30min), the equipment will automatically stop the seal fan, open the bypass
damper, close the outlet damper.

Close the ash discharge system as required.

— Generally the operation of the ash discharge system should be kept for short shut-down.
— Close the ash discharge system according to the dust level for long shut-down.
Monitor the shut-down progress from the display in the control room.
For the short shut-down, the hopper heating equipment should be open. The important spot is
that short the open time of the access door when doing the maintenance and inspection. During the
short shut-down, the ash discharge system should normally be in operation.
For the normal shut-down, the bypass damper is to open one by one at the interval order of 3s,

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Two outlet dampers are to close when one bypass damper is opened, All outlet dampers are to close
when all bypass damper are opened.
(2)Protect shut-down
Protect shut-down conditions
1） Inlet temperature of FF ＞170℃ (Anytime)
2） Inlet temperature of FF ＜120℃
3）Compressed air pressure for instrument uses ＜0.5MPa
Damper operation during protect shut-down
When meet the conditions in previous section, each channel of the bypass dampers is to open
one by one at the interval order of 5s, and close the outlet damper in proportion at the same time.
Recover of the protect shut-down
3min after each condition recover to normal condition, all dampers will automatically recover
to normal working condition, the manual operation is not needed.
(3)Automatic shut-down
When the resistance of FF is 1500Pa (Adjustable) bigger than the high operation setting value
of the differential pressure，if the duration surpasses the time setting 30min, the system will
shut-down automatically.
When the resistance of FF is 1800Pa (Adjustable) bigger than high operation setting value of
the differential pressure, the system will shut-down automatically.
When the system is in normal operation, 2 or above outlet dampers of any channel is in closed
condition, the bypass damper will automatically open, the system will automatically shut down.
3.6 Special measures
3.6.1 When the bags are new, the gas can easily pass through the fabric and the dust can easily
acculumate in the bags. The resistance, however, will increase gradually, and cause a serious result.
When fire with oil, some oil mist has not burnt and may also stick in the bag surface, which drop the
ash cleaning capacity. Follow the procedure specified below when the bags are new to protect the
bags and prolong the service life of it. Make the precoating with the TH special response assistant to
the new filter bags, let the new bag surface evenly covered with the precoating.
Precoating procedures as below:
1）Switch off the bag cleaning system
2）Turn on the relevant outlet damper, close bypass damper.
3）Turn on ID fan, air flow rate should be equal at least above 70% load of the air quantity, in
order to carry away the precoating material and equispace it to each filter bags. Then inject the
precoating material (TH special response assistant) to the front fule duct of the dust collector, it’s
better to be injected with canned vehicle. The injection quantity is 500g/ m2
4）After precoating, open bypass damper, close outlet damper.
When the boiler puts into operation, the dust collector can not start the cleaning system before
the thermal state gas passes the filter bag.
3.6.2 Renstatement of the bag filter compartment
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 When the work in the compartment has been completed
1） Ensure that no tools or other objects are left in the compartment.
2） Close the access door, put into the ESP.
3） Turn the inlet baffle and outlet damper of this compartment to the “Program control”
position from the PC, let the inlet baffle and outlet damper automatically open.
4） Verify that bypass damper and outlet damper have assumed correct positions
All dampers and seal fan can be operated on the PC. For remote operation, the local control box
should be in “Remote” position. There is interlock program for outlet damper and bypass damper, it
can not be blind operated. During the operation, bypass damper will automatically open if the two or
above outlet dampers are in close position. Press “Manual” button if want to operate damper, press
“Open” or “Close” to control damper, Press “Manual” button if want to operate seal fan, press
“Start” or “Stop” to control fan. Operation picture is as below:

3.7 Breakdown alarm

This section contains the description of the alarm indications, which can be shown on the PC.
Generally alarm indications shows on each picture, when the alarm breaks out, examine the
corresponding alarm。
All informations, such as alarm times and dates and so on, can be inquired from the alarm
summery pannel, press the alarm confirmation after the alarm disappears, then the occurred alarm
informaton will be deleted from the summery pannel, alarm switch controls the start-up and
shut-down of the alarm, operators should not turn off the alarm to avoid the alarm information can
not display when the alarm occurs. Follow the below picture:

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 When an alarm is activated, the operator should try to identify the alarm and the cause of
alarm as soon as possible, take the corresponding measures positively, in order to avoid the
serious result.
The process image to which the alarm belongs can be called on the display and provide
information on the alarm. As an alternative, the operator can request a list of alarms to be shown on
the display to facilitate identification of the alarm.
Unless otherwise specified the actions recommended are based on the assumption that sensors,
swiches etc. are in working order. If, therefore, an alarm remains in spite of the actions taken, these
components should be checked for proper function.
NOTE! Always turn off and secure the relevant safety switch before any breakdown
finding or repair commences to avoid the boiler cold stoking.
The alarm content and measure may refer to the following:
a、 Damper alarm
Instruction: Damper position is not normal, travel switch, solenoid valve breakdown, gas
path leakage, valve control box not to ventilate, or gas supply pressure of the instruments is
insufficient.
：1）Measures: Check that whether the air pressure is normal, the gas path is unblocked,
the gas valve is open.
2） Adjust the valve by hand, to check that whether the valve is in normal
operation, if not, overhual the valve.
3） If the valve is in normal operation, then contact the electrician to inspect that
whether the travel switch is normal.
NOTE! When adjust the inlet & outlet baffle, must guarantee that the inlet & outlet baffle
positions of other compartments are normal, in order to avoid that the bypass damper
automatically open when the inlet baffle or outlet baffle is in closed position.
b、 Low pressure alarm of compressed air for instruments, injection gas
Instruction: compressor breakdown, gas path leakage, pulse valve can not be closed, gas
supply is insufficient.
1） Measures: Check the compressor.
2） Check the gas path.
3） Check the relevant pulse valve to see the history curve and to judge the
working condition of the pulse valve.
c. Superelevation warning of differential pressure
Instruction: Differential pressure across the dust collector >1500Pa.
：1）Measures: Ensure that pulse injection is in operation condition, judge the operation
condition of pulse valve by history curve, if the pulse valve has not acted, check that
whether the PLC is in normal operation and the power fuse is burnout.
2）Refer to chart 2 “Breakdown maintenance guide”.
d. High-low temperature alarm

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 Instruction: The dust collector is going to the bypass operation mode when high
temperature protection setting is bigger than (170℃) or smaller than (120℃) at the FF
inlet. This temperature is the temperature predicted value of 3 temperature transmitter,
the computation principle is as follows:
 If the difference between the maximum and median is bigger than 30℃,
then discard the maximum.
 If the difference between the minimum and median is bigger than 30℃,
then discard the minimum.
 Eliminating the unreasonable temperature value, the maximum value is
used for opening the bypass damper when the high temperature protection,
the minimum value is used for low temperature protection of FF.
The high temperature must be brought down by taking measures. The FF will put
into operation automatically after the temperature reduces to the appropriate value.
e. Differential value of diffenential transmitter >100Pa alarm
Instruction: Sending out the alarm when 2 differential values are >100Pa
1） Measures: The testing pipeline of differential pressure is blocked and cleans up.
2）Pressure testing tube is broken or unconnected, inspect and overhaul that.
3）The instrument is not accurate, adjust that.
f、Differential pressure transmitter alarm
Instruction: The data displayed on the monitor at this time is 0 or 3000Pa (the range is
0-3000Pa), and yellow shining.
：1） Measures: No analog signal input, differential pressure transmitter is broken or
unconnected, or wrong connected, the electrical personnel rechecks and
confirms.
2）Input channel of analog quantity is broken, check and maintain the module.
3）No power supply for analog quantity module, check the power fuse of input
module.
4）Differential pressure testing tube is blocked, caused that the differential
pressure of the transmitter surpasses the reading scope of the measuring range, clean up the pipeline.
g、 Temperature transmitter alarm
Instruction: The data displayed on the monitor at this time is 0 or 300℃ (the range
is 0-300℃), and yellow shining.
：1）Measures: No analog signal input, temperature transmitter is broken or unconnected,
or wrong connected, the electrical personnel rechecks and confirms.
2）Input channel of analog quantity is broken, check and maintain the module.
3）No power supply for analog quantity module, check the power fuse of input
module.
h、 ressure transmitter alarm
Instruction: The data displayed on the monitor at this time is 0 or 1000kPa (the range

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 is 0-1000kPa), and yellow shining.
：1）Measures: No analog signal input, pressure transmitter is broken or unconnected, or
wrong connected, the electrical personnel rechecks and confirms.
2）Input channel of analog quantity is broken, check and maintain the module.
3）No power supply for analog quantity module, check the power fuse of input
module.

Erection specification

4.1 General specification

All personnel who work with the dust collector equipment, even temporarily in connection with
inspections, are to be informed about the following safety instructions, as well as about any general
and local instructions which apply to the quipment. The person responsible for seeing this is done is
the foreman concerned.
Due to the risk of falls, helmets and safety belts with ropes or automatic fall protectors must
always be used when working in or on the plant where there are no protective railings.
If gases and/or dust are dangerous for humans, workers must protect themselves against these
emissions, and if these occur in the air in dangerous of irritating quantities, breathing masks must be
used. There are two types of breathing masks, a partial face mask which leaves the eyes uncovered,
and a full face mask which also protects the eyes. Dust filters, gas filters, and combination filters, as
well as the possibility to connect a fresh air supply from the compressed air system, are available to
both types of mask.
Note! Every gas requires its own special type of filter.
There is no universal filter available. A breathing mask with a filter may only be used when the
oxygen content in the air is greater than 20%, otherwise compressed air must be used for breathing.
In those cases where a breathing filter is sufficient, the locally responsible safety officer is to specify
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the type of filter to be used.
If the oxygen content is below 20%, of if the gas consists of many different elements, such as in
flue gases, it is necessary to use fresh air from the compressed air supply.
If the plant has been idle for an extended period of time so that it has cooled down, protective
clothing, consisting of a dust or chemicals protection overall with hood, rubber boots, rubber gloves,
and a complete mask, is required. The protective clothing used is to fit snugly around the full mask,
gloves, and boots.
When work is completed, protective equipment must be cleaned in such a way that no personal
injuries occur.
4.2 Special specification
Personal protective clothing shall be used in accordance with the earlier section “General
Specification”.
Only specially trained and appointed personnel may work in the plant.
In connection with work on fans, conveyors, or other motordriven equipment, the safety
switches to the appropriate driving motor must always be in the OFF position and locked. A mark
plate of “WORK IN PROGRESS”, together with details about the foreman responsible, shall be
posted on the safety switch concerned.
The keys to cabinets and switch device are to be stored so that unauthorized persons cannot get
holf of these.
In order to prevent fire, and to avoid inhibiting an evacuation, the plant shall be kept clean and
not used for unauthorized storage.
4.3 Working in the FF
In connection with all work in the bag filter, two people must always be present, one of which
must be designated as responsible. Both are well versed in versed in the operation of the filter, and
the risks associated with the gases and the dust present in the FF.
Handheld tools and lights which are used inside the FF may not be connected to a higher
electricity supply than 50V.
Welding or cutting inside the FF may not take place without special authorization (Normally the
filter bags should be removed when weld and cut operations.)
Handlamps and other equipment which is used inside the FF compartment shall be equipped
with protective cages to avoid damaging the filter bags.
The following measures shall be taken before commencing work in the bottom hopper, the bag
compartments, or in the nozzle house:
 Stop the plant in accordance with the section “Shut-down”
 Check that the inlet and outlet dampers are closed, for example, it is need to open
one damper during the maintenance, block the damper mechanically.
 Shut off the compressed air supply to the pulse valve.
 Chek that there are no dangerous gases left in the FF be aware of the risk for a dust
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 explosion.
 Open all access doors and secure them in the open position. Ventilate the filter until
the internal temperature has dropped sufficiently to allow access.
NOTE: The temperature of some parts in the FF may still high, so pay attention to the
personal security.
 Check that there has been no excessive build up of dust, which can be a potential
fall risk. If there is a build up of dust, ensure that the dust has been discharged
before entering into the FF. Besides, try to find the reason of the dust build up prior
to starting the filter again.
 Exercise care during all work in the FF. In the event of nausea, giddiness or
tiredness, stop all work immediately, and go out in the freash air. Ensure that a new
gas check is made at the place of work.
4.4 Overhauling the damper
Always secure the damper in the closed position and secure the damper mechanically.
4.5 Countermeasures when FF breaking out of fire
 Immediately shut down the boiler.
 Change to bypass operation and reduce exhaust gas flow.
 Call the fire brigade.
 Stop the dust discharge equipment.
 When the fire has been put out (after a number of hours), Take the following action:
 Don closefitting clothing and full mask.
 Check that the fans are running at minimum speed.
 Open all doors and hatches in the building to ensure good ventilation at the top of the
filter.
 Carefully open the access door of the dust hopper and check the extent of the fire.
 Check all bags, and replace damaged ones (see the section “Remedial maintenance” in
Part 2)
 Inspect and clean the interior of the FF.
 Start the plant in accordance with the section “Start-up” （Operation instructions）.

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