Electrostatic Precipitator

Training Seminar
Mechanical Upgrade and Retrofit
Overview

1. Mechanical Troubleshooting
2. Upgrade and Retrofit Case Study
OVERVIEW:
Mechanical Troubleshooting
1. Casing Leak

2. Gas Distribution System

3. Anti-Sneakage Baffle Plate

4. Rapping System

5. Collecting Plate

6. Discharge Electrode

7. Insulators
1. Mechanical Troubleshooting (Casing Leak)

Inlet cone leak Roof sheet corrode

Leak from manhole Roof sheet repaired

1. Mechanical Troubleshooting (Casing Leak)

Casing

Evidence of in-leakage, cross wind

Dust blow up at leakage area Leak at flexible joint & inlet duct
1. Mechanical Troubleshooting (Casing Leak)

Expansion joint leak Dust build-up in inlet duct

Corroded casing wall Water leak from top

1. Mechanical Troubleshooting (Casing Leak)

Dust build-up near access door area Dust build-up in outlet duct

Corroded casing near outlet

duct Corroded casing at outlet nozzle
2. Mechanical Troubleshooting
(Gas Distribution System)

Eroded GD screen Dust build-up on GD screen

Detached GD screen Poor water spray

2. Mechanical Troubleshooting
(Gas Distribution System)

Detached GD screen Detached GD screen

Broken turning vane Broken turning vane

3. Mechanical Troubleshooting
(Anti-Sneakage Baffle Plate)

No baffle plate Detached baffle plate

Deformed baffle plate Broken baffle plate

4. Mechanical Troubleshooting (Rapping System)

Worn out hammer arm Dropped hammers

Loose hammer Missing hammer

4. Mechanical Troubleshooting (Rapping System)

Worn out bearing Worn out bearing

Worn out pin wheel Worn out anvil

4. Mechanical Troubleshooting (Rapping System)

Worn out bolt Jammed hammer

Broken rapping insulator Misaligned shaft

4. Mechanical Troubleshooting (Rapping System)

Worn out support

Aged hammer
4. Mechanical Troubleshooting (Rapping System)

Cover Phenol Tube &

Base Plate

Coil

Plunger height check

Lower
Hammer
Cover
(Plunger)

Caution:
Worn out of metal plate cause malfunction of MIGI
4. Mechanical Troubleshooting (Rapping System)

Leakage from gland packing

Broken rapping insulator

for MIGI rapper Leakage from gland packing
5. Mechanical Troubleshooting (Collecting Plate)

Cracked CP Cracked CP Bent CP

Manhole Leakage Arc cut mark on CP

5. Mechanical Troubleshooting (Collecting Plate)

Worn out interlock on CP

Missing bolts on CP suspension

beams
6. Mechanical Troubleshooting
(Discharge Electrode)

Broken DE frame Dust build up

Loose DE and DE frame

6. Mechanical Troubleshooting
(Discharge Electrode)

Arc cut on DE frame Detached spiral DE Stress Corrosion

Detached DE bracket Bent DE

Detached spacer
7. Mechanical Troubleshooting (Insulators)

Dusty support insulator Dusty lead-in insulator

Dusty rapping insulator Moisture on HV insulator

7. Mechanical Troubleshooting (Insulators)

Spark mark on support insulator Cracked support insulator

Water mark on support insulator Dirty post insulator

Upgrade and Retrofit Case Study
CONTENTS

• CE & DE Replacement
Case Study 1 (Indonesia)

• Retrofit MHI to ELEX

Case Study 2 Type (Malaysia)

• CE Dummy Plate
Case Study 3 (Thailand)
1. CE & DE Replacement
 1. CE & DE Replacement
Problem Statement:
1. Missing & bent DEs and bent DE spikes
2. Missing & bent CEs and missing CE interlock
3. Cracked & holes on CE
4. Dust build-up on CEs & DEs
Project Time Frame: 2 weeks
Solution:
1. CE & DE replacement with new design from Tai & Chyun
Bent CE Bent DE
1. CE & DE Replacement

New CEs New DEs

New stabilizing bars Installed R clip &

stabilizing traverse
 1. CE & DE Replacement
1st Field (No-load Test)
SCR Firing Angle
Sec. Voltage (kV) Sec. Current (mA)
10 8.2 44
20 11.3 60
30 14.8 178
40 19.5 431
50 26.4 639
60 29.3 1003
70 33.2 1411
75 36.5 1498

 Benefits:
1. Static or no-load test showed a 1st Field (Air-load Test)
SCR Firing
better performance of the ESP. Angle Sec. Voltage Sec. Current
After the replacement of CE and (kV) (mA)
DE, the secondary current (mA) 533
50 24.9
has reached the maximum with
only ~75° of firing angle. 957
60 29.8
2. Dynamic or air-load test showed 1285
that the secondary current (mA) 70 33.5
can reach maximum as well with 1495
75 36.4
only ~75° of firing angle.
2. Retrofit MHI to ELEX Type

2. Upgrade MHI to ELEX Type (Raw mill ESP)

Problem Statement:
1. Poor reliability
2. Broken DE and weak rapping system
3. Customer prefer RDE
Project time frame : 24 days
Solution:
1. Upgrade MHI to ELEX design
2. Upgrade DE to RDE
 2. Retrofit MHI to ELEX Type

Original New
No. of field 2 2
Gas passage 12 14
Height m 6.5 7.8
Length m 4.5 3.39
Gap m 0.4 0.3
Flow m3/hr. 34,350 56,800
Inlet dust g/m3 40 40
Outlet dust mg/m3 35 100
 2. Retrofit MHI to ELEX Type

Scope:
 GD screen
 Support insulator
room
 CP system
 DE system
Dismantle Install internal part
 Rapping system

Install GD screen Cement casing

 2. Retrofit MHI to ELEX Type
Benefits:
1. Dust emissions reduce from 180 to 40
Dust (~180 mg/m3) mg/m3
2. Reliability of part (RDE and side
Flow (80t/h) rapping)

Before
Flow (80t/h)

Dust (~40 mg/m3)

After
3. CE Dummy Plate
 3. CE Dummy Plate
Problem Statement:
1. Broken CEs due to high corrosion rate
2. Poor reliability of old CEs
Design Criteria:
1. Not stainless steel (Expensive and minor dimension change)
2. Not increase thickness (maintain weight & rapping performance)
Solution:
Reinforcement with dummy plate
3. CE Dummy Plate

 Benefits: Field kV mA
1. Inlet field can run at maximum 1 48 429
secondary current (mA) ±450mA
2 41 446
2. There is no abnormality observed
since reinforcement 3 45 450