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Subject and Coverage This instruction defines the operating conditions, verification criteria, methods of adjustment, trial run, operation, maintenance and troubleshooting, and safety points for attention concerning electrostatic precipitators(ESP) This standard is suitable for the commissioning, operation and maintenance and management of dry and plate ~type, horizontal SY-model ESPs in industries of thermal power generation, metallurgy, paper-making, building materials and chemicals etc. This standard can be used as reference code for GP-model and ZH-model ESP, not for wet and vertical ESPs. 2. Quoted standards ‘The items of the following standards are part of this manual through quoted standards. For all quoted ones with marked dates, its following revised lists which exclude mistaken content or revised edition don’t apply to the manual, however, related department which have agreed on the manual are encouraged to research whether the latest edition is available. For all cited standards without marked dates, its latest one is suitable for the standards Quoted standards Erection Manual of Electrostatic Precipitator (REV.C) 3B6406-1992 Electrostatic Precipitator—technical specifications of Commissioning, Operation, and Maintenance JBITS910-1997 Technical Specification of Electrostatic Precipitator GB/T13931-1992 Electrostatic Precipitator—Methods of Performance Test 3. General ESP is a highly-efficient, energy-saving equipment for air cleaning with high superiority such as high collection efficiency, large gas volume to be treated, long service life, low-cost maintenance. At present, public demands on environmental protection are more and more stringent, ESPs are more commonly used. During the operation of an ESP, its operators’ manual must be strictly followed. Any points without mentioned in the standards should be handled according to the requirement of relevant drawings and technical documents 3.1 Desoription of model numbers: The main model numbers with the designation of from our company as follows: Sk, OIL A ME Uh Bw eM 67 http://wwe. betianming. com AEM: 311800 AH: Co08G) 0575-87119573 HH: (0086) 0575-87119565"hc BB 8 BB 4B (REV.C). -wmemn 26S SY 3% M -2x -140 2 Effective height of electric fields (dm) Effective width per cell (dm) Number of cells in parallel per ESP Passage spacing code for 400mm (H is 300mm) Effective length per field (dm) Number of fields per ESP Plakt -steel structure Number of ESPs in parallel per boiler Note: The above model number can be simplified as 250 Number of fields per ESP Effective cross-sectional area (250m?) 2 sy Flakt- steel structure Number of ESPs per boiler. (2 sets) 3.2 Application conditions of conventional ESP The range of ESP application as follows: Gas volume to be treated: <4.5%105m?/h Flue gas temperature:<400 (>250 is within high temperature model) Specific resistance:1x10°~ 1x10. om Spacing of same electrode:'250~ 600mm Pressure drop across ESP proper:— 4.0x10*~ 0Pa (among of this :— 1.0*10‘~ 0Pa is as normal model; — 4.0x10‘~1.0x10"Pa is as high Pressure model) Shhh: WC eR Se OTS http://www. hatianming. con 1s MIG: 311800 iH. (0086) 0575-87119573 EH: (008E) 0575-87119565i : a a eS BEA RB B(REV.C). Passage spacing: 250~ 600mm Dust concentration of inlet flue gas <100g/Nm°(under normal status) ESPs can be used to treat flue gas that contains corrosives material (called anti-corrosive ESP). ESP are not applicable for the treatment of inflammable and explosive gases (For these should be done special treatment). When working conditions for designing is beyond application range of the standard, its quality basis should be in conformity with those stipulated in the technical agreements such as technical agreement document. 4. Principle of electrostatic precipitator The principle of dust collection in an ESP as follows: When passing through the high voltage electrostatic fields, dust particles will be charged by colliding with positive ions, negative ions and electrons among electrodes or in the ion dispersion movement, The particles with electrons and ions on them will move and accumulate on the electrodes of opposite polarity under the influence of the electric field By means of rapping, the layer of dust particles on the electrodes will be dislodged into the bottom hoppers. Practice has shown that the higher the strength of electrostatic field, the more effective as ESP will be and it is preferable to capture dust particle in an ESP operation with negative corona, therefore, our ESPs are designed as the structure of high voltage negative corona electrodes with flow chart as follows: SE: AGEL A ee SE re eh eM 67 F hvtpi//www. hatianming. com 20 WSs 311800 RLF. COORG) 0575-87119573 feI: CORE) 0575-87119565,8 AE 2 2 (@ FB HDB (REV.C) Flue gas ! Positive ion [——*) Adherence HV field Gas ionization Free electron J Negative ion »| Adherence t Flue gas Positive Field a Wiad v e ——>| particte influence |————>_T0_ negative electro. ——4] Negative |__,] Field —_—-+} To positive electrode particle influence Rapping il ¥ Rapping Dislodgment Distodgment |_| seh: MLSE TSB o7 Ss e+ 311800 |__| Hopper Ash http: Ws: COORG) 0575-87119573 fe IE. discharge //ewy. betianning. com (0086) 0575-87119565 a fonesa fk 8 8 JAE (REV.C)- 5.Briefing of the equipment Structurally an ESP is divided into two portions: electrical portion and mechanical portion. Its main components and functions are described respectively as follows: 5.1 Electrical Portion The electrical portion comprises high voltage DC power supply including to their control system and low voltage control system. 5.1.1 Conventionally we use Model GGAJ02 high voltage power supply. The designation of the model as follows: GG AL 2 | controt with thyristor +i immersed and self-cooling Silicon rectification Use for high voltage Such a sct of power supply usually consists of high voltage transformer rectifier, auto-control cabinet and reactor or high impedance transformer rectifier and auto-control cabinet. This power supply can automatically adjust the voltage applied to the electric field according to the changes of gas conditions therein and can adjust the spark ratio in the field at the optimum level according to feedback signals from current so as to achieve the effects of dust collection in the best way. This power supply is equipped with perfect interlocking protective system, It is possible to set extra computer management system and upper level machine in the power supply followed by customers’ request 5.1.2 Low voltage control system and its functions: a, Programmable control of rapping for both collecting and discharge electrodes; Control of heating for high voltage insulators and heating temperature; Control of indication and alarming for ash level; Control of ash removal and transmission; Control of safety interlocking for doors, holes and cabinets; Functions of electrical heating of hopper; Measurement and indication of inlet and outlet flue gas temperature; Set up the functions and paraineters of low voltage system through Remote Supervisor Unit; i. Indication of comprehensive signals and alarm. Note: Above functions are set according to needs. Femoneg 5.2 Mechanical portion This portion can be structurally divided into internals, casing and auxiliaries. $.2.1 Internals 5.2.1.1 Collecting system Sebk. HL EMH OTE http://www. hztianming, com 8: 311800 MIF: (0086) O575-87119573 HH: (00RG) 0575-87119565 220h 8 1B LH REV.C). mene 74S The collecting system consists of suspension devices, collecting plates and shock bars ete. Collecting plates are shaped with steel coil 1.2 to 1.5mm-thickness plate on the special rolling machine. Currently, our company can provide two kinds of collecting plates ——480C type and 735C type. The curtain of collecting plates linked together must have better rigidity and its plan flatness should be kept within the specified limits so as to ensure the limited deviation of distance between collecting plates and discharge electrodes. 5.2.1.2 Discharge system The discharge system consists of suspension devices and top horizontal beam, vertical beam, upper, middle and lower frames, discharge electrodes. The discharge electrodes — emitting electrode are manufactured with special equipment. Two types can be offered by our company i.e series of tubular barbed wire and spiral wire which are key parts of ESP. Suspension for discharge system are used to support the discharge system from the top girder and collected with negative polarity of high voltage. The function of plane structure which is composed of vertical beam, top horizontal beam and angle bar, etc is to fix the upper, middle and lower frames and discharge rapping shafts. The upper, middle and lower frames are the holders of discharge electrode. 5.2.1.3 Collecting rapping system consists of drive, shafting, plain bearing etc. Normally it is driven from the ESP side. 5.2.1.4 Discharge rapping system consists of drive, vertical shafting, big and small pin wheels, rapping shafts, rapper bearing etc.(for top-driven design) or of are drive device, rapping shaft , rapper bearing etc, (for side driven design). Rapping devices are of great importance to ESPs. By rapping, dust accumulated on both collecting plates and discharge electrodes ere dislodged and fallen into hoppers. Both collecting and discharge rapping systems use rotary hammers to carry out side rapping. Since the rapper bearings are attached to the elements of discharge system at negative high voltage. A porcelain shaft insulator is inserted to isolate the high voltage between two runs of the same emitting rapping shaft. 5.2.2 Casing 5.2.2.1 Inlet nozzle (inlet funnel) Inlet nozzle is the transition between inlet duct and casing of the field. There are two or three layers of gas flow distribution plates inside the inlet hood to make the passing dust laden gases from duct enter the whole field as even as possible. The gas flow will speed down when passing through the nozzle, some larger dust particles will accumulated by natural sedimentation on the nozzle and gas distribution screens, thus some ESPs treating flue gas with clogging dust particle, distribution screens for rapping are laid, which its structurally similar to collecting rapper. Atk, HE SS KH 67S bttp://vev, het ianming. com HBA: 311800 HI: (0086) 0575-87119573 HEH; (0085) 0575-87119565as and eon 8 of and the les. am, The Hal ved om tal ad re SBIR RRR Oe SEARS 4 fh & ABB (REV.C) 3.2.2.2 Outlet nozzle(outlet funnel) The outlet nozzle makes clean flue gas go into the exhaust flue duct, which its structure and shape have relevance to gas flow distribution. Under normal conditions, 2 row of outlet gas distribution plate (channeled plates with no holes) is installed at the interface between the outlet nozzle and the casing. 5.2.2.3 Roofs Roofs consist of inner roof and outer roof, of which the top girder is a key element as it carries larger loads between collecting and discharge system. Since higher voltage power from the power supply (either at the top or on the ground )is fed in the discharge system through the top girder. To ensure good insulating status of insulators, heating devices are installed inside the insulator compartment to maintain its dryness, which two types can be adopted: electric heating or electric heating plus hot air heating. 5.2.2.4 Casing Casing is made up of columns, side panels, end panels, pipe bracings, etc as support components of steel casing of ESP and together with inlet and outlet nozzle and upper and lower roof and hopper, form a sealed container. There are access doors on the side panels. 5.2.2.5 Hopper Ridge Beam(bottom beam) and hopper Hopper ridge beam is used to connect components of casing with hopper. Hopper is a container which used to collect dislodged dust. Anti-sneaking baffles are installed inside the hopper, which prevent flue gas from bypassing the hopper, thereby leads to reduction of collecting efficiency. The hopper must have a correct valley angle to ensure that ash can flow down by itself in the hopper. To avoid condensation occurrence as a result of dust temperature dropping below dew point, heating device is usually installed on the lower part of hopper (in some cases all over the hopper). Alternatives of hopper heating are either electric heating or steam heating. From the flange at the hopper bottom, pneumatic ash conveying system or gate valve and discharge valve can be connected. 5.2.3. Auxiliaries 5.2.3.1 Ladders and Platform These are provided for easy access to different locations at various levels so as to facilitate ground operation and daily maintenance 5.2.3.2 Support bearings Support bearings located between ESP proper and support elements (concrete pillars or steel columns). Its function is not to support heavy loading from ESP, but compensate displacement caused by thermal expansion since ESP is a hot body in operation while its support elements are cold. Support bearings are usually taken the form of plate type of compound material (friction pad) as slide bearings. Plane ball bearings are sometimes used in ESPs of medium size or smaller. 5.2.3.3 Thermal insulation. To guarantee an ESP in normal operation and prevent flue gas temperature bb. MILAM MR eo 67s http://www. hotianming. con 24 Wi: 311800 BIE: (0086) 0575-87119573 4H (0086) 0575-87119565te 59 22 ab A A BEA B (REV.C)~ from dropping below dew point due to thermal dispersion, thermal insulation should be laid over the ESP casing. ‘The function of the thermal insulation is to reduce heat exchanging. By applying thermal insulation, the minimal gas temperature must be guaranteed as high as 20°Cto 30°C above dew point. The structural design of ESP thermal insulation should specify the kind of insulating material, thickness of main lagging and respective quantities. 5.2.3.4 Earthing The ESP is operating under high voltage and normally with negative corona which means its casing and collecting system have the same potential. To protect high voltage equipment and ensure person safety, the ESP must be earthed reliably with requirements as follows: ‘a. Resistance of the earthed grid can reach less than two ohms all the year round. b. The arrangement of the earthed grid should be such that the surroundings have an even voltage to ground. 6. Installation, Check and Adjustment of Equipment 6.1The installation of the equipment should meet the requirement of Erection Manual of Electrostatic Precipitator (REV.B) 6.2 Check and Adjustment of Equipment Respective check and adjustment of mechanical portion and electrical portion should be properly made in order to guarantee ESP under safe and normal running after the equipment is erected and prior to its being put into operation. 6.2.1 Check and Adjustment of Mechanical Portion 6.2.1.1 Make second corrections to some deformed or bent collecting plates and discharge electrodes in the electric fields to ensure that all the distances between opposite electrodes are kept within the following deviations: for ESPs with height of collecting plates H< 7m and the deviation is 7mm and for H>7m,+10mm. 6.2.1.2 Make adjustments in the electric fields wherever the distance between parts at high and low potential is Jess than the distance between opposite electrodes. 6.2.1.3 Check all the bolts and nuts to see that they are tightened and welded firmly. 6.2.1.4 Check to see whether contact positions between the rapping hammers and anvils are exactly as required in the approved drawings and the shafts and hammers can rotate freely. 6.2.1.5 Remove all foreign materials left inside the electric fields 62.1.6 Check whether the motors for dampers, rapping, ash discharge, etc. have the correct direction of revolving and turn freely and the chains are mounted with proper tension and each of locations of lubrication have been oiled and greased. For methods of commissioning, refer to Appendix B of Erection Manual of Electrostatic Precipitator (REV.B) 6.2.1.7 Check whether all support insulators are mounted steady under even SA bk. HULA ME MD KM OTS hetp://aww. hatianning. com 25 ME. 311800 iS: (0086) 0575-87119573 AEH+ (0086) 057587119565 oo Paae das dof ona be car gs on on al 4 ie: AE ABE HS REV.C)~ tuene 74 BAA distributed loads and are kept dry &clean. 6.2.1.8 Check to see that different parts of the ESP casing and all inspection doors are well sealed. Make gas-tightness tests followed by Appendix B of Erection Manual of Electrostatic Precipitator (REV.B) . 6.2.1.9 The rapping system is designed on the principle of improving dust cleaning effects and reducing dust re-entrainment, enhancing dust collection efficiency, lengthening service life of rapping elements and minimizing the degree of complexity of electric control for rapping. For details, specify the ESP electric technical agreement of the project. After a period of trial run, the rapping system is to be constantly adjusted to its optimum mode according to observed actual situation. 6.2.1.10 For details of the ON-OFF of dust discharge valve on the lower hopper specify the ESP electric technical agreement. Pneumatic ash conveying system is used, there is no need for ash discharge valves. In such a case, the hopper outlet is directly connected with the ash transmitter and the discharge of ash is controlled by the level detector of the inlet valve on the transmitter. 6.2.1.1 Actual gas distribution devices are designed and manufactured on the acceptable results of gas distribution model tests with a scale model, which the simulated tests are made by our company. So no adjustment tests for the gas distribution devices are made on site. 6.2.2 Check and Adjustment of Electric Portion 6.2.2.1 Measure the ground resistance of the ESP proper with available value below two ohms. 6.2.2.2 Measure insulation resistance of high voltage net work by using a 2500V megameter under normal weather and make sure it is larger than 500 mega-obms, 6.2.2.3 The cable between the ESP casing and the positive terminal in the HV T/R should be kept as whole part and fastened. 6.2.2.4 Use a S00V megameter to measure the insulation resistance of all motors and their cables , of which its insulation resistance is not less than 0.5 mega-ohms. 6.2.2.5 The operating mechanism in the high voltage isolating switch should have high mobility and be placed in the exact position. 6.2.2.6 Check to observe that all wiring in the different electric parts is correctly laid as per approved product drawings. 6.2.2.7 Adjust the spark frequency in the electric field according to electric conductivity of flue gas and required collection efficiency. There is a control potentiometer showing the rates of or voltage climb and drop on the high voltage control cubicle, which its function is to adjust spark ratio through a pair of indication lamps with longer life for flashover and quenching. When there is a flash of spark in the electric field the electronic flash lamp will shine once, so the spark frequency can be counted with a stopwatch or adjust spark rates within the following range: 30 to 60 sparks/minutes for inlet field, 20 to 50 sparks/min. for middle fields and 10 to 20 sparks/minute for outlet field. If the figures are ik. SHINS ee 67 http://eww. hztianning. com 26 Sf: 911800 IS: (0086) 0575-87119573 #3 C005) 0575-87119565~tmans 241 found to be improper after_a period of operation, then adjust them until an optimum one is reached. Microprocessor-controlled thyristor transformer rectifier has multiple functions such as automatic tracing of sparks, hence it 6.2.2.8The set value of the thermostat for insulator heating is normally around 15 to 25°C above dew point of flue gas. It is required that when the ‘emperature falls below the inferior limit, the electrical heaters are energized on its insulating. 6.2.2.9 Electric control circuits are to be adjusted Properly according to Specified rapping and ash discharge system. 6.2.2.10 For various items in electric commissioning refer to Appendix B of Erection Manual of Electrostatic Precipitator CREV.B Jor instruction manual offered by electric manufacturer. 7. Safety Regulations of equipment ESP operators and those who work temporarily on an ESP must strictly abide by standard JB6407 with general knowledge on safety as basic requirement. There should be specialized personnel are to be in charge of safety. 7.1 Personal safety 7-1-1 ESP is an high voltage installation, so Special attention must be paid to one is allowed to enter during the operation of the ESP. All inspection doors must be interlocked for safety. 7-13 Boards or signs bearing “Danger! High voltage!” must be hung on each of the control cubicles in the control room, cable trays & trenches and inspection approached by non-operators. 7-1.4-ESP is a metal operating equipment at high altitude. Ladder, platform and handrails must be reliably firm and solid. No accumulation of water or snow is existed thereon. All the walkways should be free of odds and ends or needless objects, Ha. HAM EM ROH 67g betp://www. hatianaing. com MEM: 311800 iE: C0086) 0575-87119573 fH: (0086) 0575-87119565© Baas st fe AL WON H (REV.C ARE wil an Tock ‘ormer 7.1.6 ESP is an dangerous installation at high temperature, high negative nee it pressure and dusty, so no part of the human body is allowed to touch any hot erfect part in its operation. When the ESP is shut down for inspection/maintenance, the inspection doors should be opened to cool down via ventilating and people can ind enter when the internal temperature drop below 40°C. 2 the 7.1.7 If any inspection door is left opened during the operation of ESP with sized, negative pressure status, anyone near the door is likely to be sucked in due to The high negative pressure as a result of body injuries and even electric shock er of accidents by high voltage, therefore, the doors must be securely interlocked. s led 7.1.8 Personnel enter the ESP must weer safety helmets, well-sealed protective 1 for overalls, shoes and gloves ete after its shutdown. ture 7.1.9 To prevent human bodies from being infected by smoke and dust, wash the wind body and protective overalls after the construction is finished. vects 7.1.10 Wear gas masks when construction staff enter inlet of the ESP where = there is too much dust and smoke. 7.2 Safety checks of Equipment 7.2.1Make regular checks of the earthing cable and other connections to see if a they have good electric conductivity and other protective devices are in good ide at, order. 7.2.2 Make sure that all the locks on boxes for relays and switches are reliable, 30 irrelevant personnel can not open them easily. 7.2.3 The portable lamps for use inside the ESP must be as lamps with safety voltage. 7.3 Safety Measures during T/R Maintenance 7.3.1Make sure that the transformer-rectifier (T/R) has been cut off with its safety switch in exact “OFF” position and locked with a lock 7.3.2Check to see that all the switches on the control panel are in “OFF” positions. 7.3.3 A sign showing ‘I/R Under Repair!’ should be placed in an eye-catching position in front of the control panel. 7.3.4 Check whether the earthing terminal is well earthed. 7.3.5 Earth high voltage parts of the T/R with the earthing devices provided 7.3.6Make sure the above procedures have been executed before T/R maintenance. 7.4 Safety Measures for Maintenance inside ESP 7.4.1A sign showing ‘ People Inside ESP” should be placed in an conspicuous position in front of the control panel. 7.4.2Eor maintenance inside the electric field of the ESP , at least two persons are needed and one of them is in charge.of monitoring. Maintainers of ESP must be familiar with the design and structure of the ESP as well as the function of its various parts/components. They should also know the properties of the flue gas and the dust, their potential harms and the effective protective measures to be taken. She: IL AH RET HD 5 Be 67S http://www. hetianning. com 28 311800 iS: (0086) 0575-87119573 fe 3C: (0086) 0575-87119565he Bb 18 8 HB REV.C)-~ amunn 74 SHRI 7.4.3 The shutdown of an ESP and Personnel to enter it should ‘ollow the regulations listed below: a, Strictly follow the relevant specifications stipulated in the items of 7.1; b. Carry out the related procedures stipulated in the items of 7.3; c. Turn off the safety switches of all rapping motors and the motor for ash discharge valve and secure them with locks; 4, Tum off the HV isolating switch, secure it with a lock and earth the discharge system with the earthing devices provided; e. Turn the switches of ESP blower and ID. fan to “OFF” position and secure them with locks; £, Shut off the dampers on ESP inlet and outlet ducts, turn off electric actuators of damper and secure them with locks; g. Open all the inspection (access) doors to ventilate the ESP internal. When the temperature drop below 40°C, people can enter. To speed up the process of cooling, the dampers in outlet duct can be opened and the I.D. fan can be turned on. But in such a case, the access doors must be locked in the “OPEN” positions to avoid sudden closing. h, When maintainer enter the ESP, they should be aware of the risk of being scalded because of different degrees in cooling for different parts /components i. After entering the ESP, maintainers should first inspect to see if there is dust accumulated somewhere with potential of danger. If there does exist, clean it to avoid accidents. At the same time, the causes for dust accumulation should be worked out. j. When the maintenance is over, maintainers should check their tools at lest some of them are left to impair ESP function. 8. Trial Run of Equipment 8.1 To ensure the ESP in seliable operation, before a new installation is put into formal service after erection and commissioning or before an old one is to resume operation after a long period of stoppage, a pre-operation trial run must be made. 8.2 Procedures of trial run for the equipment 8.2.1An experienced engineer should be appointed to be a general director of the trial run. And the items to be checked should be planned and strict records on site should be kept and special personne! should be designated to register. To avoid damages caused by condensation of moisture in flue gas or by not inspecting all the parts/components during operation, the following checks should be made: a. Check to confirm all the items listed in 6.2 above have been carried out with acceptable results; b. All the doors of thermal insulated boxes are locked; c. All the inspection doors are closed and interlocked; d. Check the open& close of flue duct dampers to ensure reliable operation both manually and electrically; Sb LL a MEK OTS hetp://wuw. hztianaing. com 29 MM; 311800 GIR: (008) 0575-87119573 4H: (0086) 0575-87119565‘hb oA Oe FH I B(REV.C) smune YORSaRIK® . Check the functions of alarm on the electric control panels by prevsing the ‘TEST ‘buttons thereon to simulate alarming; £. Check to see if the power net voltage is correct; g. Check to confirm that no one is inside the ESP or in other dangerous areas with high voltage: 8.2.2 After all the pre-operation items of inspection have been made with acceptable results, perform the following operations: a, Turn on the electric heaters in the each insulator compartment; b, Start up the motors for rapping and ash discharge and observe each parts and keep them running for 30 minutes; ¢. Detach the earthing devices from the high voltage parts to have an open circuit between the discharge and collecting system; 4, Turn off the HV isolating switches on the power units and lock them in the operation positions. : 8.2.3 Energization—Turn on the automatic voltage-adjusting system and observe the rising for no-load voltage. 8.2.4 Keep records of the changes of primary and secondary voltage and current. Since the no-load current has something to do with the temperature and humidity of the air. At the very time of trial run with no-loads, pay attention to the capacity of the equipment and values of voltage and current 8.2.5After the trial run with no-loads is over, analyze and eliminate all the breakdown occurred under the trial run. 8.2.6 Plot the voltage-current characteristic curves for each electric field. Mark the values of voltage corresponding to a certain degree of rising in current on a sheet of coordinate paper until the current reaches its rated value. Connecting these points together will form a piece of curve, which is called voltage-current characteristic curve and can be used as reference for the check of erection quslity and comparison with later no-load curves of the same electric field . 8.2.7 Keep records of the on-load primary and secondary voltage and current. 8.2.8 Plot the on-load V-A curves and work out analysis to them by the same methods. 8.2.9 Re-check the air leakage in the ESP casing and inspection door etc. 8.2.10 Shut the ESP down(Procedures of shutdown refer to item9.5). 8.2.11Check the inner wall of the support insulator and the shaft insulator and two sides of the gas distribution screen to see if there are phenomena of rapid dust accumulation and damages. 8.2.12 Eliminate all the troubles occurred during the on-load trial run. 9. Operation Regulations of the Equipment 9.1 The ESP should be operated and managed by professional people who have comprehensive knowledge on performances of the equipment, requirements of operation, safcty and maintenance and are familiar with this manual. The owner of the ESP must first have these qualified by means of examination and check before they are to be operated and managed the ESP 9.2 Before the start of ESP operation, make a final strict check of the equipment, Stk, BILAN SEM RE 67 S http://wwv. hetianning. com 30 4 Wi. 311800 AF. (0085) 0575-87119573 HH: (0086) 0575-87119565Hs Bk 28 4 FAR 45 (REV.C)- RBRRE va ih iA keep inspection records for each items and the records should he signed and approved by the person in charge of field operation. 9.3 Start-up procedures of ESP 9.3.1 Make sure that pre-operation inspection is over, all the safety measures are taken and all the operators are in place. 9.3.2 All the heaters have been turned on for at least 8 hours prior to start-up of ESP, which ensure inside the all hoppers and various insulators (support insulators, shaft insulators, etc) are dry and to avoid any damage caused by electric creepage owing to condensation. Check all electric heaters to see if the current is correct. 9.3.3 Open all the dampers in inlet and outlet flue ducts (but with the exception of those in inlet and outlet interconnecting sections). 9.3.4 Start up the LD. fan. 9.3.5 Lead flue gas into the ESP to eliminate the moisture on various internals This period of warm-up depends on the temperature and humidity within each field and is usually ended when the temperature at the outlet of the last field reaches higher than gas dew point. At this time be sure to let go the moisture from within the insulator compartments. When the temperature of gas at ESP outlet remains lower than dew point, never put the high voltage T/R into operation. When the Boiler fire with oil, never put the high voltage T/R into operation. (Expect the ESP for the oil fired Boiler) 9.3.6 Start up the ash discharge system. 9.3.7 Start up all the rapping devices. 9.3.8 Turn on all the functions of the low voltage operating system. Set alarms, safety interlocking, temperature detector and controller, ash level indicator, ash discharger, etc. are all in a mode of auto-controlled operation. 9.3.9 The ESP can’t put into operation until the boiler is in steady operation with firing coal and the temperature inside ESP is higher than gas dew point. And it should be operated with zero spark rate. 9.4 Operation process 9.4.1There should be sufficient staff on duty in the ESP control room. They should make regular checks to the operation of the equipment. For occurrence of abnormal phenomena, analyze the causes of breakdown and solve them. For each work shift, at least two checkers should be made to the transformers and all rotary devices to see if they function properly and check oil inspection of speed reducer and adequately grease. 9.4.2 Main items to be inspected are as follows: a. Check to see whether the operating current of each heating system is correct, b. Check all the indicating lamps and alarms to sce if they function properly; c. Check to see if the values of primary current A and primary voltage V and secondary current mA and secondary voltage KV as indicated by. the rectifiers are correct. JOSE, HORT RS Kw 67S hee HM: 311800 hi: (0086) 0575-87119573 fe Jovy. hatianning. com 31 (0088) 0575-87119565Be Xe teaain” BRASH CBW REVC) emeRR BBS and d. Check to see if the ash discharge system has any problem in discharging the collected ash; e. Regularly check to see if the rapping shafts turn normally and the hammers sare hit properly (as can be heard from outside of ESP). 9.4.3 Observe and optimize the spark ratio, rapping sequence and ash discharge pot program of cach electric field until a satisfactory collection efficiency is port = obtained. by = 9.4.4 The staff on duty must keep records of the operation siatus of the the equipment with carefulness, especially values of the primary and secondary _ current and voltage, which are to be recorded per two-hours. on 9.5 Shutdown procedures of ESP 9.5.1 Temporary shutdown a. Switch off the I.D. fans and wait for three to five minutes; us. = b. Switch off, in the order of electric field, the high voltage power source to wh | E each bus section and have the control cubicles locked. qd c. Shut off all the dampers in both inlet and outlet flue ducts; we 4. Keep on running for heating systems during temporary shutdown; sp e. Any person isn’t allowed to enter into field of ESP. to E 9.5.2 Long-term shutdown to a, Complete the procedures steps a, b and e in 9.5.2.1 above; b. Turn off the high voltage isolating switches to each bus section and turn it in the earthing position and have it locked; c. Shutdown all systems of heating, temperature measuring controlling and 3 E ash level controlling; h 4. Keep on operating the rapping and ash discharge systems after high voltage power supply is cut off until all the smoke and dust are cleaned and removed inside the ESP; ©. Turn off the main power switch, excluding lighting; E 9.6 For operation of the electric portion, refer to Electric Instructions of electrical equipment. 10. Maintenance and troubleshooting of Equipment } To achieve the reliable operation of ESP in long term with required collection E efficiency, professional personnel should be appointed to be is charge of ESP operation and maintenance. These people must know the design, principles, functions and performance of the ESP and are able to operate and to maintain and to troubleshoot the ESP. During each shutdown of ESP, a general check should be made to clean its inside and correct the deformed plates and electrodes and clean the insulators of dirt and measure the earth resistance and eliminate all defects occurred during its previous operation. Normally an ESP needs a minor overhaul once a year, of which items includes the replacement of worn parts. The ESP need major overhaul every third year(or followed by overhaul schedule of the boiler). Overall cleaning and adjustment are done in electric field and replacement of some defective or worn parts/components are made, moreover, lubricants are to Se, MAUL A tH KB 07 S hetp://wow. hatianaing. com 32 68+ 311800 tH: C0086) O575-87119573 HH: (0086) 0575-87119505,5 i 2 25 FL OF HB (REV.C) be changed at regular interval. 10.1 Routine checks and maintenance 10.1.1 After entering the BSP, first check if there are any phenomena of dust accumulation and clean these. 10.1.2 Check the side panels, access doors and insulator compartments at the top of ESP to observe if there are phenomena or air leakage, condensation, corrosion or dust accumulation, if there are, eliminate them. 10.1.3Check the motor temperatures oil level in speed reducers, shaft bearings and rapping hammers to see if they are in good order and if the hammers hit on the correct locations. Lubricate the motors as per manufacturer’s manual. 10.1.4 Sometimes the gas distribution screens may have dust accumulations or blockages somewhere due to low gas velocity thereon. Check and clean manually. 10.1.5 Check the discharge frames and discharge electrode to ensure that they are not deformed and that there is no dust deposition. 10.1.7 Check the collecting plates and shock bars to ensure that they are not bent and that there is no dust deposition. 10.1.7 Support insulator is used to support and insulate for discharge system. Possible cracks result from high voltage breakdown due to accumulated dirt and moisture, thus clean inner and outer wall of the insulator and search for tiny crack by using a flashlight. In order to suck thermal air to reduce contamination from internal support insulator, two slot holes(Smm to 10mm) of its cover plate are left. 10.1.8 Clean the shaft insulators in discharge rapping shafts and search for possible flaws with a flashlight. 10.1.9 With reference to the manufacturer’s manual, check the HV T/R sets to see if the functions of the high voltage isolating switches, relays, heaters, instruments for temperature measuring and controlling, alarms, earthing devices. etc, are normal and eliminate the breakdown if there are any. 10.2 Warning 10.2.1 Take strict precautions against excessive accumulation of ash in field of ESP Heavy dust accumulation in electric fields are usually caused by failure of dust discharge system or its insufficiency of conveying capacity. Maybe dust adherence or ‘bridging’ in hoppers on account of hopper heaters with breakages and poor thermal insulation, and it make the ash can’t discharge smoothly in time, Huge amount of dust piled in hoppers, when it continuously accumulates and touch electrode, it will inevitably result in short circuit in electric fields. The rapping system of collecting system will be damaged. The collecting plate will be moved out from its suspension frame. The emitting frame will be deformed. It accordingly makes the electrical field malfunction and result in severe problem. We should pay extra attention to this situation. At this period, the field has been stopped running, but the boiler is still working. Large numbers of dust hereby still fall into hopper by gravity. If there is excessive Sib: TLL we 67 http://eww. hetienning. con ABH: 311800 iF. (0086) 0575-87119573 fe HM: (0086) 0575-87119565 330p on on or an E i [ E i § i se ih 2 ALE B REV.) -ansns ZOReyein® deposit of dust in the hopper and that is not discharged in time, it will» -alt in « severe and nonreversible damage of ESP. So the exigent method for discharging the dust should be made to prevent the ESP from being further damaged, the details as follows: a, Avoid over deposit of dust in hopper. Check the actual operation condition of conveyor system, when the high level detector alarms, and take measures to make the dust conveying unhindered. It will reduce the level of dust and conceal the alarm. b. When dust deposit in any of hoppers is over its upper level and make the switch break out, exigent measures must be taken to discharge the dust in extremely short time. The dust discharging should be done in 3 hours and the deposit level is lower than the upper opening of the hopper in 8 hours fo make the field working again. c. If the dust discharging is not done in 8 hours, mandatory measures must be taken, for example, cutting a hole near the outlet of hopper, open the hand hole for discharging the dust, ect. 4. If every great efforts has been made in 48 hours, and the dust in hopper is still beyond the upper opening of hopper, and the switch is still out of work, the generator and boiler have to be compulsively shut down to make sure of safety and avoid worst results. ©. Pay extra attention to the safety when the dust be discharged from hopper, especially the bridging dust, because it will drop suddenly if effected by other outer force. Besides this other accidents such as scald should also be avoided. 10.2.2 No safety measure, No allowance for entering into electrical field 10.2.3 Nobody is allowed to go to the ESP roof, otherwise the professional person of ESP 10.3 Analysis of comprehensive defaults and their solutions SO, WLS EM 67g http://www. bztianming. con WER. 311800 RIF: (0086) 0575-87119573 fe: (008G) 0575-87119565 34BG 2 HAE LR 5 (REV.C) senna % No. Defaults. Possible Causes Remedies 1 |The secondary voltage rise up, end flash. secondary |(I)Possible earthing from working current is large, HV part electric material. by forcign conductive can’t |(2) The character of high no specific resistance of dust and flue gas change the corona voltage. (3)HV sampling loop in contro! cabinet has malfunction and discharge tube are under soft breakdown condition, or the meter gets stuck. (4)The discharge tube comprised of paralleled HV sampling resistance in T/R is under soft breakdown condition. TyExamine the field and insulator compartment, then remove the foreign material. 2)change the type of coal or adopt gas extender. 3)Repair the HV loop and change the. ~—-broken. component. 4)change the component. broken, Mish, eT ew SE TT RBH OTS ego. 311800 iB: ntep://wrw. betianping. com 35 (0086) 0575-87119573 18 3€: (0086) 0575-87119565 ee a(a ica anune YI 2 |The secondary | (1)Insulator is seriously | 1).Repair or replace the current is}contaminated or —_ its |heating elements or normal or a heating elements are out | insulation equipment. little bigger, the }of order and poorly | Clean the surface of the second voltage | insulated, resulting in | insulator.When flue gas can’t rise up. condensation on the | temperature is lower than insulator surface, hence|its dew point, the | decreasing the insulation | equipment can’t be put into Property and surface | operation, | creepage or flue gas temperature in field is lower than that of dew point, this leads to the same consequences as above. (2)Heavy dust deposition | 2)Check and adjust it. ‘on both collecting and discharge systems, thereby shortening their actual distance. (3)The erection error of | 3)Check and adjust it. voltage distance is too dig. (4) Poor welding in casing | 4)Make remedial welding or access doors are not|in the leakage of casing sealed well, result in} and shut the access doors cold air rushing in and to | tight. deform the internals and to decrease voltage distance. (5) Collecting plates and | 5)Examine the _ fixation emitting wire are | mechanism of collecting swinging, and it causes | and emitting system severe flashover at low voltage. (6)Full of dust in hoppers | 6) Make the ash discharge and dust approach or | and transmission systems contact discharge system, | work properly, clean the resulting in reduction of) dust blockage in hopper, 25 fi 18 89 45 (REV.C)~ insulation Property | check heating clements of between opposite | hopper, and keep the dust electrodes. never be clogged in hopper. : (7) Lower output voltage | 7) Check HV T/R from T/R; (8) Larger voltage drop | 8)Check the system loop. in other parts of the loop (such as with poor earthing). Joab, HAM ROH oT Ss http://ewx. hatianning. con 36 eM: 511800 I: C0086) 0575-87119573 eH: (006) 0575-87119585,se RA aE OE ALB (REV.C) secondary current. J [Severe flashover | The depositing dust in Aller the Held trips, It] ged trip occur in [hopper increases greatly | should discharge the dust in field and even exceeds the 3 hours, and make the dust upper opening of hopper [be lower than the upper and buries lower parts of | opening of hopper, keep the the collecting plate and | field can work normally emitting wire and make | again. If the dust can not be the insulation character | cleaned in 8 hours, forcible greatly decrease measurements must be made such as cut a hole on lower part of the hopper, open the hand hole for clean the dustjete. If every great effort has been made in 48 hours, the dust is still not lower than the upper opening of hopper and the field is still in trip situation, the boiler and generator have to be compulsively shut down to make sure the safety, and to avoid worst results F [inregular changes | Dust deposits on Remove the accumulated of secondary | electrodes and sparkover | dust current occurs where the voltage distance is smaller. 3 | Periodical The remaining part Replace the broken wires. changes of | swings after a string of secondary current | discharge electrode is broken 6 | There Ist (1) Excessive dust loading | Dlmprove the technological secondary voltage | cause corona blockage. | process fo reduce dust but nor loading in flue gas. Petemely little | (2) Severe dust deposits |2) Intensify rapping and on collecting and discharge systems; (3) Higher ground resistance and poor high voltage loop; (4) Broken circuit in the measuring loop of ampere meter in HV loop. (5) Poor contact between HV outlet and electric field. (6)Pointer of milli-ampere meter gets stuck remove deposited dust. 3) Reduce the ground resistance to the specified value. 4) Rectify the circuit. broken 5)Check the connections and make them in full contact. 6)Repair the meter. Sbk, MALS MET OR SR 67S Hig: (0086) 0576-87119573 48: Wi. 311800 a hetp://wew. hetisnaing. co8 HL: (0086) 0576-87119565 j= Kt 2 28 Ah LB 48 (REV.C). anune 7AIRBIR® 7 Excessive spark, (Wet air leaks in through access door, damp gas from leaking boiler or _ dirty insulators. (2)Poor contact of secondary side in T/R or the diode of, rectifier bridge is open-circuit. |) Uneven gas distribution. (4)Passage distance becomes smaller. (5)The hopper is full of dust or there is dead angle of dust depositing in field, that result in bad dust discharging. 1)Take cowesponding corrective measures. 2)find out the reason then repair or change. 3)change the gas flow screen. 4)adjust the distance, S)clean the depositing dust. passage (6)The damping resistance | 6)change the — damping breaks and discharges. resistance. Shik, MILA BS Kah 67 S hetp://www. hztianming. com 38 Mii: 311800 HE: CORE) 0575-87119573 HI. C0086) 0575-87119565,cnune 2AIERIS sy a AF 18.8 H5(REV.C). 8 |The primary and | (1) The error of voltage | 1)Adjust it, secondary current| distance is too big. & voltage are all | (2) Uneven gas|2)Remove the dust or normal, but distribution, _gas | replace the gas screens collection screens blocked by efficiency is dust, lower, (Excessive air leakage |3) Make remedial welding causes change —_in | where there is air leakage. operation condition: increase of gas velocity, decrease of temperature, weak charging possibility of dust particles, ete. (4) Much higher specific | 4) Condition the gas quality resistance of dust particle, back-corona may exist, slow charge neutralization in dust layers on electrodes and rapping is unable to dislodge them due to significant adherence. (5) The control parameter |5)Repair or replace the is not set in reason. power supply. (6)Conditions of gas | 6)Collection efficiency entering the ESP do not| should be calculated by accord with the original | using correction curves ones, resulting in changes | under the actual working of operation conditions. | conditions. 7) Mechanical problem TRepair as needed, if such as abnormal rapper. | rapping is not sufficient, make it rotate freely or instead of heavier hammers (8) Gas flow by-passes | 8)Check gas baffles and due to fallen gas baffles | solve the problem. in hoppers. 9 | Stuck ash | (1) Hammer Drop Shut down the equipment to discharge device, | (2) Foreign substance in | repair or tripped discharge mechanism safety device and blocks of coke fall into ash discharge device. (3) Broken chain, in case a drag_—chain conveyor is used. SGik. WI AN EM EM OTS Ing: 311800 http://wew. hatianming. com WH iG (0086) 0575-87119573 42H: (0086) 0575-87119565 39oa 46 EH (REV.C). : srane 26IGRR [10 Control is out of order, and the alarm trip. (I)The SCR is breakdown. (2)The touching off line of SCR disturbs or pinouts is short circuit, (3)The primary side of T/R is earthed or short circuit. The sampling loop of secondary side of T/R or the minus HV is earthed. Or the sampling loop of circuit and voltage is short circuit Find out the reason then repair or change. Ti TIR output is out of control (1) Breakdown of SCR (2)Disappeared feedback and sample resistance damaged . (3)The setting of parameter is wrong. 1) replace the parts. 2) check related elements and loops. 3)adjust the parameter, meters on panel during voltage adjustment (2)No outlet impulses; (3)Broken —_quick-break fuse; (4) Open circuit in thyristor elements; (5) Broken sampling loops for AC & DC; (6) Poor ‘contact of change-over switch for measurement in AC voltmeter 12 | Control and main /(1) Safety interlocking is | Iyeheck the access doors loops do not | not in place, and cubicle doors of for function their exact closure. @)Interlocking for HV | 2)check the HV isolating switch are not in | disconnecting for their exact the exact position; closure. (3)Broken closing winding and loop; 3)check the line and replace (Poor contact of | the winding auxiliary switch 4)Repair the switch. 13, )No indication |(1) Poor contact of loop |I)Check the line and Toop from lamps on | elements; elements panel when | (2) Burnt bulbs 2) Replace the bulbs. energized G)Burnt fuse. 3)Replace the fuse. 14 [No indication of | (1)Paults inside the meters | 1) Check and calibrate the meters, 2)Use an oscilloscope to determine the amplitude and number of outlet impulses, 3) Replace. 4) Replace 5)Check the secondary wiring and contact points of switches. 6)Check the touch point of switch. Shit: MICA RTRS sm 67 S 8H. 311600 BB. coves) 0575-ar119573 http://www. het ienming. con eH: (0086) 0575-87119565a Be 4 8 EAL BLA HR (REV.C)- - mane AIRS” 15 There is signal on _flashover indicator but no corresponding actions on other (1) Foreign interference. (2) Signal transform is blocked by flashover and 1) Check the shield earthing status. 2) Add a by-pass and replace elements. meters of the | failed elements. panel. 16 | Secondary ()Excessive width of the | i)Change the parameters to voltage "won't | first blocking pulse adjust the pulse width. rise upon the flashover. automatically | (2)The given value of rate | 2)Enlarge the given level. upon a flashover, | of voltage but initiates an | rise+Av /At is too low. alarm 7 17 | During on “load” | (1) Open cirouit in current | 1) Check the secondary voltage step-up, | sampling loop. wiring. there is normal | (2) Internal line breaks in|2) Measure the sampling voltage but zero | the ammeter. voltage. current. 18 | During voltage [(1) Open circuit and false|}1) Lift the T/R core for step-up, primary | soldering point in T/R|checks and eliminate the voltage secondary winding and | defaults adjustment is | silicon stack. normal, but] (2) Insufficient safety }2) Check and relocate the secondary distance from HV inlet to | HV inlet voltage exists | ESP casing. and disappears |(3) Open circuit in DC|3) Lift the T/R core for alternatively and | sampling voltage dividing | checks and repair. is accompanied | loop. by noise of discharge 19 | Tripping of [Breakdown and short | Lift the TVR core and alarm for oil | circuit of T/R secondary | replace the damaged parts. pressure; odour | winding or silicon stack of ozone from TR. 20 | Tripping and | T/R oil level below the oil | Make troubleshooting and alarming of | lower limit, add oil to suitable level signal. from oil level 21 | Tripping of | Plue gas within gas relay. | Open the discharge valve to alarm for oil get rid of the gas. pressure WS. HALE RH Km 67S #84: 311800 al 4 % hetp://wwm. hztianning. com 41 iH (0086) 0575-87119573 AH. (0086) 0575-87119565